Impeller Outlet Research Articles

Simulation and Optimization of Start-up Process of High-speed Gas-liquid Two-phase Pump

Background: Centrifugal pump is widely used in industrial production as a key fluid conveying equipment. The transient characteristics during its start-up process may lead to vibration, noise and efficiency loss. Therefore, it is very important to optimize the start-up process. Objective: Optimize the structural parameters of the centrifugal pump, with the initial pulse values of both the head and efficiency as the optimization objectives, to enhance its transient performance. Methods: The centrifugal pump was numerically simulated by computational fluid dynamics method. In the optimization process, the BP neural network is established, and the genetic algorithm is used to optimize the parameters, which improves the efficiency and accuracy of parameter tuning. Results: The optimized head pulse value is reduced by 4.39 m, and the efficiency pulse value is reduced by 5.65 %. Make the start-up process of centrifugal pump more stable. Conclusion: Among the parameters that affect the stability of the centrifugal pump start-up process, it can be obtained that the three factors of impeller outlet width, blade outlet angle and blade wrap angle have the greatest influence on the fluctuating head and efficiency of the centrifugal pump. other: none

Performance assessment on DES/DDES method for transient flow in a centrifugal turbomachine model subjects to rotor-stator interaction

We present an assessment of the performances of the detached eddy simulation (DES) and delayed detached eddy simulation (DDES) approaches in resolving the transient flow in a system of a centrifugal impeller and a vaned diffuser which is strongly destabilized by the rotor-stator interaction (RSI). The numerical results obtained by the DES and DDES approaches are compared against that from an independent large-eddy simulation (LES) investigation and that of a vaneless diffuser model. The time-averaged and fluctuating velocity, the nonlinear primary momentum transport term, and the two-point correlation of fluctuating pressure in the impeller, diffuser, and vaneless region are analyzed. The numerical results reveal that the diffuser vanes substantially perturb the flow inside the impeller, especially at the impeller outlet. The DDES approach cannot resolve the multi-scale flow structures in the vaneless region. The DES approach produces a time-averaged velocity field that is more consistent with the LES approach, and the DDES approach performs better for the reversed flow. For the transient behaviors, the DES approach is more sensitive to weak fluctuation, and for the pressure fluctuation in the impeller where the RSI significantly perturbs. The DDES approach gives a consistent two-point correlation of fluctuating pressure with the LES approach, while the DES approach could not give an accurate prediction.

On unsteady flow characteristics in a water-jet pump based on proper orthogonal decomposition method under different inflow conditions

Considering the complex flow characteristics of the water-jet pump and the anisotropy of Reynolds stresses, a hybrid Reynolds-averaged Navier–Stokes/large-eddy simulation method based on von Kármán scale and nonlinear correction has been developed, while its effectiveness has also been verified. The proper orthogonal decomposition method is employed to study the unsteady flow characteristics inside a water-jet pump due to its advantages in flow field analysis. The internal and external characteristics of the water-jet pump under two kinds of inflow conditions are comparatively analyzed, and the intrinsic influence mechanism of nonuniform inflow on the performance of the water-jet pump is investigated. The results indicate that nonuniform inflow causes the overall decrease in the pump head curve, and occurs serious reverse flow at impeller outlet near blade tip region, which in turn generates a large energy dissipation. The flow state is relatively smooth under uniform inflow condition, while the nonuniform inflow makes tip leakage flow induce many unstable flow structures, causing large turbulent kinetic energy and low pressure difference between the pressure surfaces and suction surfaces of impeller blades. There are multiscale flow structures in the water-jet pump, with large scales corresponding to low-order modes, which play a dominant role in turbulent movement and can be used as an important element for evaluating hydraulic performance. The energy content of low-modes is lower and the distribution of flow structures in each-order mode is more chaotic in the water-jet pump for nonuniform inflow compared to the ones for uniform inflow.

Numerical Simulation and Model Test on Pressure Fluctuation and Structural Characteristics of Lightweight Axial Flow Pump

In order to explore the relationship between the hydraulic performance, pressure pulsation, and structural characteristics of lightweight axial flow pumps, this paper takes the axial flow pump as the research object and analyzes pressure pulsation and structural characteristics by changing the blade length and thickness to realize the lightweight design of the axial flow pump impeller. Compared with the initial scheme (Scheme 1), the mass of the impeller is reduced by 17.2% (Scheme 2) and 29.9% (Scheme 3), respectively. The lightweight axial flow pump (Scheme 2 and Scheme 3) has a lower pressure pulsation amplitude at the impeller outlet monitoring point under large flow conditions. After the lightweight design of the axial flow pump impeller, the blade becomes shorter, the mass becomes lighter, and the cavitation performance will become worse. The maximum equivalent stress of Scheme 2 and Scheme 3 is increased by 2.8% and 31.9%, respectively, compared to Scheme 1. The maximum deformation of Scheme 3 increased by 27% compared to Scheme 1. This research can provide guidance for the lightweight optimization design of the axial flow pump.

Analysis of Flow Loss Characteristics of a Multistage Pump Based on Entropy Production

To reveal the internal flow loss characteristics of a multi-stage pump, the unsteady calculation of the internal flow field of a seven-stage centrifugal pump was carried out, and the entropy production theory and Q criterion were utilized to analyze the unsteady flow characteristics of each flow component under different flow rates. The research results show that as the flow rate increases, the entropy production value and the energy loss inside the flow components also increase accordingly. The viscous dissipation entropy production caused by fluid viscosity is very small, and the turbulent dissipation entropy production caused by turbulent fluctuations and wall dissipation entropy production are the main sources of energy loss. The impellers, diffusers, and outlet chamber are the main regions of energy loss in the multistage pump. The entropy production value of the first-stage impeller is significantly higher than that of other impellers, while the entropy production value of the first-stage diffuser is significantly lower than that of other diffusers. Through vortex structure analysis, it is found that the high entropy production regions in the impeller are concentrated in the impeller inlet area, the blade suction surface, and the impeller outlet area.

Efficiency improvement and pressure pulsation reduction of volute centrifugal pump through diffuser design optimization

To investigate the effects of load distribution parameters of the diffuser vanes on the efficiency and pressure pulsation of the volute centrifugal pump, the diffuser shape was designed using an inverse design method, and an optimization method was proposed for the diffuser blade load distribution based on the combination of Latin hypercubic sampling, artificial neural network, and non-dominated sorting genetic algorithm-II. Steady and unsteady simulations were performed by solving the three-dimensional Reynolds-averaged Navier–Stokes equations using the shear stress transport k−ω turbulence model. The results obtained from Pearson correlation analysis revealed that the slope values Ks and Kh of the shroud and hub load distribution curves had the most significant effect on the pump head and efficiency. Compared with those of the original model, the efficiency and head of the optimized volute centrifugal pump under the design conditions increased by 3.8 and 3.5 %, respectively. The pressure pulsation intensities in the vaneless regions were effectively mitigated for the optimized volute centrifugal pump. The pressure pulsation coefficients at three times the diffuser vane frequency (3fDIF) reduced by 58.5 and 43.8 % at monitoring points M1 and M2, in the impeller outlet, respectively. The pressure pulsation coefficients at the impeller blade passing frequency (fBPF) reduced by 6.5 and 14.4 % at monitoring points M3 and M4 in the diffuser inlet, respectively. The results showed that the optimized diffuser improved the overall performance of the volute centrifugal pump, and demonstrated the feasibility of the optimization method.

Fast predesign methodology of centrifugal compressor for PEMFCs combining a physics-based loss model and an interpretable machine learning method

For boosted hydrogen fuel cells, the centrifugal compressor greatly affects the system's efficiency, stack power and costs. However, the design of the centrifugal compressor is a lengthy and high-cost process. To tackle this issue, a new method combining a physics-based loss model and a machine learning method was proposed to achieve a fast and more accurate preliminary design step. A high-precision physics-based loss model was developed and validated for data generation. Furthermore, two gradient boosting decision tree (GBDT) models with Bayesian hyperparameter turning were established to construct mapping relationships between geometric parameters and aerodynamic performance. Then, the Sobol sensitivity analysis and Shapley Additive Explanations (SHAP)-based interpretability were used to explore the impact of the geometric parameters on the aerodynamic performances. Results showed that the outlet blade angle, impeller outlet diameter, impeller outlet width, inducer shroud diameter, and inducer blade angle (at the shroud) were the five most sensitive parameters. Additionally, some practical design recommendations were extracted using SHAP-based interpretability. The isentropic efficiencies of two redesign cases with optimal geometric parameters were increased by 2.59% and 1.85% compared with the baseline impellers. The performance prediction was completed within a time of 6 s using the proposed new predesign method. This study represents a significant new attempt to advance the preliminary design methodology of centrifugal compressors.

Design Improvement for Interventional Blood Pumps Based on Flow Analysis

Abstract Interventional blood pumps serve as a crucial component for temporary mechanical circulatory support in the treatment of heart failure, specifically designed to improve blood circulation recovery and survival rate in patients undergoing treatment for acute cardiovascular diseases. This study aims to design a novel interventional blood pump with a focus on achieving exceptional hydraulic performance and superior blood compatibility based on numerical simulation, which considers the interactions between the blood pump and the upstream (drainage cannula) and downstream (aorta) flow fields, establishing a full-scale flow field analysis. For the numerical method, the Reynolds-Averaged Navier-Stokes (RANS) equations coupling with the k-ɛ turbulence model are solved. The result indicates that high shear stress exists around the leading and trailing edges of impeller blades and there is a jet at the outlet of impeller, and the blade leading and trailing edge, and the outlet of the impeller are the dominant regions for higher hemolysis occurrence. It is also noted that the presence of an interventional blood pump generates significant vortex structures within the aorta. To effectively reduce the hemolysis index, back-sweep concept is applied to this study also optimize the impeller’s leading edge. The analysis result confirms that the back swept leading edge of impeller blade helps improve the blood compatibility for interventional blood pumps.

Study in Gas-Phase Agglomeration Characteristics of Spiral Flow Gas-Liquid Multiphase Pump

Abstract The spiral flow gas-liquid mixed transport pump experiences gas phase accumulation in the impeller flow passage, leading to blockage and a decrease in pumping performance. To understand the rules and mechanisms of gas phase aggregation in the spiral flow gas-liquid mixed transport pump, numerical calculations based on the Eulerian multiphase flow model and SST k – ω turbulent flow model were conducted. The effects of different gas volume fractions, speeds, and liquid phase viscosities on the pump were explored, and the external characteristics, flow characteristics, and gas phase aggregation processes in the impeller were analysed for these three variables. The results indicate that the head and efficiency of the pump gradually decrease with increasing gas volume fraction and liquid phase viscosity, while they increase with increasing speed. When the liquid phase viscosity changes from pure water to 50 times its viscosity, the gas phase aggregation at the impeller outlet decreases, resulting in reduced pressure and a smaller vortex region. The relative gas phase aggregation degree λ decreases from 0.5 to almost 0. When the gas volume fraction increases from 20% to 60%, the gas phase aggregation at the impeller outlet increases, the pressure difference between the impeller hub and the rim increases, and the vortex region expands, leading to an increase in λ by 8 times. When the speed increases from 3000 rpm to 5000 rpm, the gas phase aggregation at the impeller outlet increases, the pressure increases, and the vortex region expands, resulting in a 16-fold increase in λ.

Experimental study on energy and hydraulic performance of the axial flow pumping device with bell-shaped inlet channel

Abstract Due to the unique inlet design of the axial flow pump device with a bell shaped inlet channel, there is currently insufficient quantitative research on its hydraulic characteristics. This study investigates the hydraulic behavior of a vertical axial flow pumping device equipped with a bell-shaped inlet channel, analyzing various blade angles. Energy, cavitation, runaway, and pressure pulsation characteristics were assessed through meticulous testing on a high-precision test bench. Experimental findings indicate that altering the blade angle of the vertical axial flow pumping device with a bell-shaped inlet channel can influence its overall efficiency to some extent. Moreover, as the pump’s blade angle increases incrementally, the device’s cavitation performance gradually diminishes. Pressure pulsation tests reveal a relatively minor amplitude of pressure pulsation at the impeller outlet, contrasting with a more pronounced amplitude observed at the guide vane outlet compared to the pump outlet. These research results provide valuable insights for the design and optimization of actual pumping stations.

Prediction of Progressive Erosion Characteristics of Centrifugal Pump Blades Based on Dynamic Boundaries

Abstract The conventional method of fixed boundaries for predicting erosion inadequately reflects the erosion characteristics of centrifugal pumps under realistic operating conditions. In this research, we employ the dynamic boundary method, considering the influence of changes in wall morphology due to erosion on the flow field. We utilize the Euler-Lagrange approach and the E/CRC erosion model, incorporating a dynamic boundary geometry reconstruction strategy, to predict the erosion characteristics of the IS80-50-315 single-stage single-suction centrifugal pump. Solid-liquid two-phase flow calculations are conducted on the pump to predict erosion characteristics under varied operating conditions. The results show that the dynamic boundary-based progressive erosion prediction method realistically forecasts the erosion characteristics of the overflow wall and captures the evolution of blade morphology with erosion time. Erosion intensity on the blade suction surface significantly surpasses that on the pressure surface, guided by particle distribution characteristics in the centrifugal pump flow channel. Particle diameter primarily influences the erosion position of centrifugal pump blades; smaller particles induce erosion in the middle region of the blade, while an increase in particle diameter shifts the severe erosion position towards the impeller outlet direction. At a consistent particle diameter, higher particle concentrations correspond to elevated erosion rates in the blade area. We establish a relationship between the blade mass loss rate and erosion time during 2500 hours of pump operation at the design condition, introducing the blade mass loss rate for convenient assessment and prediction of blade damage in the centrifugal pump.

Influence of axial distance between impeller and diffuser on the hydraulic performance and flow loss characteristics of bulb tubular pump

Abstract Bulb tubular pumps used in regional water transfer projects consume substantial power. Optimizing the geometric parameters of tubular pumps is crucial for enhancing efficiency and minimizing hydraulic losses. ANSYS CFX is used to investigate the axial distance between the impeller and the diffuser on the hydraulic performance and flow loss characteristics of the rear-bulb tubular pump, and the numerical simulation results are compared with the experimental data. Then, the entropy production theory is introduced to analyze flow losses. As the axial distance increases, the diffuser’s rectification effect on the flow at the impeller outlet deteriorates, leading to increased flow losses and decreased head and efficiency of the device. Flow losses in the bulb tubular pump are ranked from largest to smallest as follows: impeller, outflow channel, diffuser, inlet channel. The impeller exhibits the highest entropy production ratio, reaching 61.05% at an axial distance of 25 mm. By elucidating the energy loss distribution of each component under varying axial distances, this paper offers insights for the hydraulic optimization design of bulb tubular pumps.

Impact of Double-Suction Pump Eye Diameter Variation on Cavitation Phenomena

Cavitation phenomena in pumps are major determinants of the lifespan of both the impeller and the pump itself, causing significant vibration and noise, which are critical concerns for pump designers. This study focuses on the influence of various geometric factors of the impeller, including the shape of the blade leading edge, blade inlet angle, number and thickness of blades, surface roughness, wrap angle, impeller outlet width, inlet hub diameter, and tip clearance. The pump analyzed in this study, which exhibited issues of vibration and noise in actual industrial settings, was evaluated by varying only the shroud diameter based on Gulich’s theory, while keeping other parameters constant, to assess the effects on cavitation phenomena across five different impellers. Single-phase analysis was initially conducted to evaluate the performance of each pump model, with the reliability of the numerical analysis methods validated by comparison with experimental data. Furthermore, to analyze cavitation phenomena, a multiphase flow analysis was performed using the Rayleigh–Plesset model within a computational fluid dynamics framework. Quantitative analysis of cavitation occurrence, NPSH3% head-drop performance, and bubble volume was conducted. The results confirmed that the M1 model, featuring a shroud diameter of 560 mm, exhibited superior cavitation resistance. Variations in cavitation occurrence observed under three different flow conditions demonstrated a nonlinear trend, but overall, improvements were noted within a specific diameter range. This study offers valuable insights and data for pump design applicable in real-world industrial settings.

Performance improvement of multi-blade centrifugal fan based on impeller outlet flow control

The impeller of the multi-blade centrifugal fan significantly impacts the fan's internal flow field and aerodynamic performance. To improve the axial flow distribution along the impeller and suppress the blade passage backflow at the impeller outlet of multi-blade centrifugal fans, a method of variable chord length blade design is proposed. Simultaneously, optimization models are established with static pressure and efficiency as objectives. By altering the control points of the Bezier curve, the leading-edge profile of the impeller is optimized. The results indicate that using variable chord length blades can expand the operating range of the multi-blade centrifugal fan. The maximum flow rate improvement reaches 10.6%. Significant enhancements in the aerodynamic efficiency of the multi-blade centrifugal fan are observed at low flow rates, with a maximum improvement of 4.9%. The variable chord length blade design method enables adjustment of the axial flow distribution at the impeller outlet to better match the impeller's flow requirements. This leads to increased outlet flow on both the shroud and hub sides of the impeller, consequently reducing the backflow area on both sides and improving the blade passage backflow phenomenon. Moreover, variable chord length blades facilitate a more uniform circumferential flow distribution at the impeller outlet, reducing the diversion pressure of the volute tongue, mitigating flow separation within the blade passage, weakening the interaction between the impeller and the volute tongue, and lowering energy losses in the impeller–volute tongue regions. Consequently, this enhances the aerodynamic performance of multi-blade centrifugal fans.

Optimization of cavitation performance and hydraulic performance of multistage pump based on response surface method

The structural parameters of the first stage impeller have an important influence on the performance of multistage pumps, and the purpose of our study is to find the most significant factors affecting the performance of double-casing multistage pumps, and then to carry out a comprehensive optimization of the hydraulic performance and cavitation performance. With the Plackett-Burman design method, we made a notability analysis on impeller parameters, and the three control variables that are most sensitive to performance of multistage pumps were found. Based on the response surface method, we carried out the central composite design experiments for the sensitive control variables, and established the multiple regression model between the sensitive parameters and the performance parameters. By solving the regression model, the most significant parameters affecting the performance were obtained: impeller outlet angle, outlet diameter and wrap angle. After analyzing the interaction between impeller parameters, it was found that the optimal hydraulic performance and the optimal NPSHr will constrain each other, and the optimal parameter combination with the lowest NPSHr and the hydraulic performance not lower than that of original model is impeller outlet diameter, D21 = 292 mm, the impeller outlet angle, β21 = 19°, and the wrap angle, φ1 = 160°.

Effects of endwall clearances of variable diffuser vane on centrifugal compressor performance

To ensure the variable diffuser vane can rotate around a pivot fluently in practical applications, there have to be clearances between vanes and diffuser walls. As the compressor pressure ratio increases, the effects of the vane endwall clearances are enhanced and cannot be ignored. This paper investigates the effects of both-side vane endwall clearances on the centrifugal compressor performance. Results show that the existence of endwall clearances mainly enlarges the flow capacity of the vane diffuser and decreases the compressor efficiency, and these effects are more significant as the vane stagger angle decreases. A one-side endwall clearance of 2.7% of the diffuser width increases the choke mass flow rate by as much as 20% and decreases the compressor peak efficiency by 2.7%. Due to the non-uniform flow along span at the impeller outlet, the shroud-side vane endwall leakage plays a more important role than the hub-side in affecting the compressor performance. In additions, the respective contributions of the vane throat, the hub-side and the shroud-side endwall clearances to the increases of the vane choke mass flow rate are quantitatively studied. The flow physics and loss mechanisms of the endwall leakage are revealed.

Effect of blade length on unsteady cavitation characteristics of hydrodynamic torque converter

Hydrodynamic torque converters (HTC), as power transmission component for high-power machinery, achieve flexible and energy saving transmission by circulating viscous oil through multi-stage impellers, involving cavitation at high flow speeds. To achieve cavitation suppression and performance enhancement, this study analyzed the mechanism of HTC blade length on cavitation effects. The Computational Fluid Dynamics (CFD) model of cavitation in the internal flow field of HTCs with different blade length were established, a hydraulic performance and flow-induced vibration test system was set up, and experimental prototypes with different blade lengths were designed and manufactured. The macroscopic and microscopic transient cavitation characteristics of different blade length were studied. The results show that shortening the length of pump and turbine blades has a significant suppression effect on cavitation. Due to changes in the impeller outlet flow field and circulation flow, the cavitation attachment range has changed significantly. Additionally, the significant impact of blade length on the flow-induced vibration influent the evolution characteristics of transient cavitation. Shorter blades reduce the amplitude of pressure oscillations, improving the attachment stability of cavitation. This study has important implications for improving the performance of HTCs and reducing the occurrence of cavitation.

Design of a partial discharge shrouded impeller for the centrifugal compressor of supercritical carbon dioxide power cycles

In this paper, the concept of partial discharge shrouded impeller is proposed to enhance the performance of supercritical carbon dioxide (S-CO2) centrifugal compressor under low flow rates, thereby increasing the overall efficiency of the S-CO2 Brayton cycle. The influence mechanism of the partial discharge shrouded impeller on the flow behavior inside the impeller domain has been revealed by computational fluid dynamics (CFD) simulation. The results indicate a notable enhancement in the pressure ratio and isentropic efficiency of the S-CO2 centrifugal compressor utilizing the best partial discharge shrouded impeller, showcasing improvements of 0.9% and 10.2% respectively under designed flow rate condition, while the stability parameter (SP) surpasses 0 at lower flow rates when compared to conventional impeller. With the partial discharge shrouded impeller, the flow separation on the blade pressure surface tends to occur nearer the impeller outlet, restricting the wake secondary flow shedding off to the diffuser, thus the flow loss being weakened. Meanwhile, with the optimized compressor by employing the best partial discharge shrouded impeller, the efficiency of S-CO2 Brayton cycle has been increased by 5% relative to that with full discharge shrouded impeller.

Effect of conversion time on the stability of mixed-flow pump in rotating speed conversion

The rotating speed conversion strategy has a significant impact on the stability of the variable speed operation of the mixed flow pump. Taking a mixed-flow pump as the research object, this paper collects the shaft vibration, pressure pulsation, and external characteristic parameters under different conversion times based on the synchronous acquisition system, and analyzes the influence of conversion time on these parameters. Finally, based on the improved TOPSIS evaluation method, the influence of different conversion time on the stability of the mixed-flow pump is evaluated. The results indicate that the conversion time is positively correlated with the amplitude of shaft vibration and pressure pulsation in the pump during the transition of rotating speed reduction. The local rubbing of the shaft can induce the vibration component corresponding to the high harmonics frequencies such as 2 f n, 3 f n, and 4 f n. The high correlation frequency band of the impeller outlet pressure pulsation and shaft vibration is located between 64 Hz and 120 Hz. And this frequency band is not affected by the conversion time. According to the TOPSIS evaluation results, in the transition process of speed reduction, the longer the rotating speed conversion time, the worse the stability of the mixed-flow pump during the conversion process.

Investigating the mechanism of flow of transonic compact crossover tandem diffuser

Dealing with high transonic airflow at the outlet of a mixed-flow impeller is a challenging issue in research on the design of efficient and compact diffusers. A low aspect ratio and an adverse pressure gradient in the passage of the diffuser can lead to flow separation on the hub side of the bend and the suction side of the aft blade. Tandem blading can be used to attain flow control through an appropriate relative circumferential tandem position (λ). However, a comprehensive understanding of flow in a compact crossover tandem diffuser (CTD) requires further investigation. This study provides a detailed analysis of the mechanism of flow in a compact crossover baseline tandem diffuser (CBTD) as well as the influence of different values of λ on the structure of flow of the CTD. The findings show that the CBTD can suppress secondary flow separation on the hub side of the bend by reasonably distributing the radial load. We also found that a value of λ of 75% can delay the point of separation on the suction side of the aft blade over a wide range of spans, where this inhibits the corner separation vortex and improves the structure of flow and performance of the diffuser. We also preliminarily explore the impacts of excitation of full-span jet intensities with different values of λ on the corner separation vortex on the suction side of the aft blade and offer guidance for the design of a compact and efficient CTD.