Combined Numerical Analysis of an Oil-free Twin Screw Compressor Using 3D CFD and 1D Multi-chamber Thermodynamic Model

The application of three-dimensional computational fluid dynamics in twin-screw compressors provides an outstanding opportunity for developers to gain an understanding of the complex internal flow phenomena occurring within the machine. Equipped with this knowledge, design parameters, such as clearances and port geometry, can be optimised, to enhance performance. However, as with all modelling, be it numerical or analytical, a high degree of certainty in the accuracy of the results is necessary. This paper presents the results of a study of oil-free twin screw compressor in which the results of two modelling techniques are compared. The modelling techniques used are an analytical non-dimensional thermodynamic chamber model and a numerical computational fluid dynamic model. The paper presents an overview of an oil-free twin screw compressor machine, before describing important operating characteristics and the modelling techniques used. To validate, both models are compared against historical test data, this validation indicated the chamber model is more accurate. Following this, the focus will be on the comparison of key performance indicators, including, volume flow rate, volumetric efficiency, indicated power, and discharge temperature at varying duty points. The paper concludes that the difference between both models decreases as the compressor operating speed increases, although the level of variance is dependent on pressure ratio

Numerical and Experimental Analysis of Transient Flow in Roots Blower

The performance of rotary positive displacement machines highly depends on the operational clearances. It is widely believed that computational fluid dynamics (CFD) can help understanding internal leakage flows. Developments of grid generating tools for analysis of leakage flows by CFD in rotary positive displacement machines have not yet been fully validated. Roots blower is a good representative of positive displacement machines and as such is convenient for optical access in order to analyse internal flows. The experimental investigation of flow in optical roots blower by phase-locked PIV (Particle Image Velocimetry) performed in the Centre for Compressor Technology at City, University of London provided the velocity field suitable for validation of the simulation model. This paper shows the results of the three-dimensional CFD transient simulation model of a Roots blower with the dynamic numerical grids generated by SCORG and flow solution solved in ANSYS CFX flow solver to obtain internal flow patterns. The velocity fields obtained by simulation agree qualitatively with the experimental results and show the correct main flow features in the working chamber. There are some differences in the velocity magnitude and vortex distribution. The flow field in roots blower is highly turbulent and three-dimensional. The axial clearances should be included, and the axial grids should be refined in the simulation method. The paper outlines some directions for future simulation and experimental work. The work described in this paper is a part of the large project set to evaluate characteristics of the internal flow in rotary positive displacement machines and to characterize leakage flow

Experimental Investigation of the Transient Flow in Roots Blower

Rotary positive displacement machines are common method to pump flow in various process industries. Their performance highly depends on the operational clearances. It is widely believed that computational fluid dynamics (CFD) can help understanding and reducing internal leakage flows. However, Developments of grid generating tools for use of CFD in rotary positive displacement machines have not yet been fully validated. Thereby arising a need to validate these models that help in better understanding of the leakage flows. Roots blower is a good representative of positive displacement machines and as such is convenient for optical access to analyse flows in in such machines. This paper describes the setup of the experimental test rig with the optical Roots blower in the Centre for Compressor Technology at City, University of London and the first results obtained using three different flow visualization methods. These are namely i) the high-speed camera (HC), ii) the continuous time resolved PIV (CPIV) and iii) the instantaneous PIV obtained with double pulse PIV laser and double shutter camera (IPIV). Test results from these three tests are compared and discussed in the paper. The CPIV test shows the movement of the vortex and the general shape of the flow field clearly but is not sufficient to calculate velocity vectors of high-velocity particles due to the limitation of the laser and camera. The IPIV test can produce quantitative velocity vector images of the internal flow but needs improvement to look into the leakage flow. The work described in this paper is a part of the large project set to evaluate characteristics of the internal flow in rotary positive displacement machines and to characterize leakage flows. The objective is to enable further improvements in 3D CFD analysis of leakage flows in rotary positive displacement machines and ultimately lead to the improvement in the performance of rotary positive displacement machines

Algebraic generation of single domain computational grid for twin screw machines. Part I. Implementation

Special attention is required for generation of computational grids in highly deforming working chambers of twin screw machines for 3D CFD calculations. Two approaches for customised grid generation are practically available. The first is an algebraic grid generation and the second is a differential decomposition method. This paper reports on new developments in the algebraic approach that has the advantages associated with both algebraic and differential methods. Two control functions are introduced for regularisation of the initial algebraic distribution. One is based on an analytical control function in transformed coordinate system while the other uses background blocking structure in order to guide the initial algebraic distribution towards a single computational mesh. This paper presents implementation and grid characteristics of these new functions. Developed grids have been tested and results from flow calculations on a dry air compressor have been validated in part II of the paper [29]. It was possible to achieve two distinct characteristics desirable in a twin screw rotor domain mesh. Firstly, it is possible to independently control grid refinement in the interlobe region thereby providing better accuracy in representation of the leakage gaps. Secondly and most importantly, it is possible now to eliminate the non-conformal interface between the two rotor domains thereby producing a single domain structured grid for the rotors, while still maintaining the fully hexahedral cell topology. An improvement in the global orthogonality of the cells was achieved. Despite of a decrement in the Face warp quality, aspect ratio of cells retained similar scale

Highly Deforming Computational Meshes for CFD Analysis of Twin-Screw Positive Displacement Machines

Commercial flow solvers can be used to obtain flow solutions in applications with deforming domains, but, in general, are not suitable for screw machine flow calculations. This is due to the large magnitude of deformation of the domain and the geometrical complexity of helical rotors. In this chapter, the governing equations for deforming domains and three methods of obtaining mesh movement, commonly used by FVM solvers, have been analysed. A comparative study of customised methods of grid generation for screw machines, using algebraic and differential approaches, is shown to help in the selection of techniques that can improve grid quality, robustness and speed of grid generation. The analysis of an oil-injected twin-screw compressor is included as a test case to demonstrate the application of SCORG, a deforming grid generator, as a means of predicting performance

User defined nodal displacement of numerical mesh for analysis of screw machines in FLUENT

Growing demands to reduce energy consumption are driving researchers towards in-depth analysis of positive displacement machines. Twin screw compressors are amongst the most common types of positive displacement machines. These machines have inherently complex geometry due to intricate rotor profiles used. As the details of the internal flows are difficult to obtain experimentally, Computational Fluid Dynamics (CFD) offers a good alternative for evaluation of internal flow patterns. However, implementation of CFD is challenging due complex deforming geometries. In this paper, a customised grid generator SCORGTM developed by authors is used to generate numerical meshes for commercially available solver ANSYS FLUENT. FLUENT is an unstructured solver which offers flexibility of using both segregated and coupled solution algorithms. Segregated algorithms are generally faster which results in shorter product development time. Interface with FLUENT is implemented by performing User Defined Nodal Displacements (UDND) of grids generated by SCORG in a parallel framework. For this purpose, SCORG and UDND are coupled and extended to work with FLUENT's parallel architecture. The developed code is compiled within the solver. The oil free air screw compressor with 'N' profile rotors and 3/5 lobe combination is modelled for 8000 RPM and 6000 RPM. Finally, the predicted performance values with FLUENT are compared to previously calculated CFX predictions and experimental results. FLUENT requires shorter solution time to obtain same accuracy of CFX

Development and Design of Energy Efficient Oil-Flooded Screw Compressors

It is estimated that about 17% of the world's generated power is used for compression. Thus all, even minor improvement of the efficiency of compressors will substantially reduce CO2 emission. This paper presents development of family of energy efficient oil-flooded screw compressors for Kirloskar Pneumatic Company Ltd. The developmental techniques adopted to improve efficiency such as introduction of superior 'N' rotor profile, rotor clearance management, performance calculation using 3D CCM (Computational Continuum Mechanics), direct parametric interface to CAD (Computer Aided Design), which contains bearing selection for complete 3D solid modelling. Also, contemporary prototyping and experimental investigation is supported by the fully computerised data acquisition and processing. The cumulative improvement of all these elements of the design process resulted in a very efficient machine which guarantees the competitive position of Kirloskar Pneumatic Company Limited in the screw compressor market

Boundary-Conforming Finite Element Methods for Twin-Screw Extruders using Spline-Based Parameterization Techniques

This paper presents a novel spline-based meshing technique that allows for usage of boundary-conforming meshes for unsteady flow and temperature simulations in co-rotating twin-screw extruders. Spline-based descriptions of arbitrary screw geometries are generated using Elliptic Grid Generation. They are evaluated in a number of discrete points to yield a coarse classical mesh. The use of a special control mapping allows to fine-tune properties of the coarse mesh like orthogonality at the boundaries. The coarse mesh is used as a 'scaffolding' to generate a boundary-conforming mesh out of a fine background mesh at run-time. Storing only a coarse mesh makes the method cheap in terms of memory storage. Additionally, the adaptation at run-time is extremely cheap compared to computing the flow solution. Furthermore, this method circumvents the need for expensive re-meshing and projections of solutions making it efficient and accurate. It is incorporated into a space-time finite element framework. We present time-dependent test cases of non-Newtonian fluids in 2D and 3D for complex screw designs. They demonstrate the potential of the method also for arbitrarily complex industrial applications

Numerical investigation of flow characteristics in twin-screw pump under cavitating conditions

In order to investigate the flow characteristics and the formation process of cavitation in twin-screw pumps, three-dimensional CFD (Computational Fluid Dynamics) numerical analysis has been carried out. A conformal structured moving mesh generated by an in-house code SCORG was applied for the rotor domain. The VOF (Volume of Fluid) Method has been adopted for dealing with the liquid-gas two-phase flow, while the bubble dynamics was handled by a homogenous cavitation model. By changing the rotation speed and discharge pressure, the intensity, distribution area and variation of cavitation at different rotor angle were obtained. The effects of rotation speed and discharge pressure on cavitation characteristics have been analysed. Calculation results with cavitation model are compared with the results without cavitation and the experimentally obtained values. The influence of cavitation on the performance of a screw pump in terms of the mass flow rate, pressure distribution, rotor torque and the shaft power have been analysed and discussed

Transient flow analysis in a Roots blower: Experimental and numerical investigations

It is widely acknowledged that rotary positive displacement machines exhibit highly unsteady flow fields that affect their performance. The presence of the operational clearances impacts this unsteady flow field and further affects the performance. However, the exact nature of these unsteady flow mechanisms remains largely unknown that necessitates both detailed experimental investigations and computational modelling. Thus, the present study employs both optical visualization and unsteady Reynolds-Averaged Navier Stokes (URANS) computational modelling methods while focussing on investigating the transient flow field inside a Roots blower, a general type of the rotary positive displacement machine. Straight lobes in a Roots blower provide convenient optical access to experimentally analyse internal flow and compare it with the predictions obtained by standard computational models. In the first part of this paper, this study covers the low-speed experimental investigations using i) High-Speed Camera (HC), ii) the continuous High-Speed Particle Image Velocimetry (CPIV) and, iii) the instantaneous PIV (IPIV) obtained with a double pulse laser and a double shutter camera. Relative merits from these techniques are discussed with respect to the Roots blower unsteady flow mechanisms. In addition, computational analyses are performed using a combination of in-house and commercial modelling methods and the results are compared against the experiments. The results confirm the existence of highly three-dimensional and unsteady flow field where certain distinct flow mechanisms originating from the operational clearances impact the performance of the Roots blower. The study also highlights challenges of the experimental and computational methods used for evaluation of positive displacement machines that impact the accuracy of results