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

Manufacturing method and performance assessment for variable lead vacuum rotors

In recent years variable lead rotors have been produced, mainly for vacuum applications, involving a multiple pass manufacturing process which is necessarily time-consuming. A faster method of manufacturing such rotors uses a full profiled disc-type milling or grinding tool but involves clearance variations along the length. These effects have been assessed by computer modelling to quantify any disadvantages. The results indicate that the effects on performance are negligible and the profiled disk tool process is suitable for such components

Normal Rack Grid Generation Method for Screw Machines with Large Helix Angles

Improving the efficiency of the screw machine is highly significant for industry. Numerical simulation is an important tool in developing these machines. The 3D computational fluid dynamic simulation can give a valuable insight into the flow parameters of screw machines. However, it is currently difficult to generate high quality computational grids required for screw rotors with large helix angle. This is mainly due to the excessively high cell skewness of the rotors with large helix angel, which would introduce errors in numerical simulation. This paper presents a novel grid generation algorithm used for the screw rotors with large helix angel. This method is based on the principles developed for the grid generation in transverse cross-section. Such mesh is generated by SCORGTM using normal rack grid generation method which means numerical meshes are generated in a plane normal to the pitch helix line. The mesh lines are then parallel to the helix line and thus an orthogonal mesh will be produced. The main flow and leakage flow directions are orthogonal to the mesh, potentially reducing numerical diffusion. This developed algorithm could also be employed for single screw machines

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

Numerical investigation of oil injection in a Roots blower operated as expander

The adoption of positive displacement machines as expanders in Organic Rankine Cycles (ORCs) is increasingly common, especially in the low to medium power range. At the same time, these devices often serve as compressor in Vapor-Compression Refrigeration Systems. In both cases, the application of Computation Fluid Dynamics (CFD) to optimize such machines has become an integrated tool in the design process. As a consequence, several challenges associated with the numerical simulation have to be taken into account. For example, the modeling of the gap represents a challenge for the stability of the numerical analysis. The dynamic of the process, combined with deformations of the clearances and of the working chamber has to be considered with extra care. To raise the efficiency of the machine, oil is typically injected. Its numerical modeling imply an extra challenge in the simulation of the actual operation of the machine. The present work is mainly focused on the multi-phase nature of the flow, with a particular analysis of the lubricant oil injected. In this work, a two-lobe Roots blower operated as expander has been simulated with the open-source software OpenFOAM-v1812, using the SCORG-V5.2.2. This analysis highlights the areas that are affected the most by the oil presence in order to highlight the sealing effect it provides

Grid generation methodology and CFD simulations in sliding vane compressors and expanders

The limiting factor for the employment of advanced 3D CFD tools in the analysis and design of rotary vane machines is the unavailability of methods for generation of computational grids suitable for fast and reliable numerical analysis. The paper addresses this challenge presenting the development of an analytical grid generation for vane machines that is based on the user defined nodal displacement. In particular, mesh boundaries are defined as parametric curves generated using trigonometrical modelling of the axial cross section of the machine while the distribution of computational nodes is performed using algebraic algorithms with transfinite interpolation, post orthogonalisation and smoothing. Algebraic control functions are introduced for distribution of nodes on the rotor and casing boundaries in order to achieve good grid quality in terms of cell size and expansion. In this way, the moving and deforming fluid domain of the sliding vane machine is discretized and the conservation of intrinsic quantities in ensured by maintaining the cell connectivity and structure. For validation of generated grids, a mid-size air compressor and a small-scale expander for Organic Rankine Cycle applications have been investigated in this paper. Remarks on implementation of the mesh motion algorithm, stability and robustness experienced with the ANSYS CFX solver as well as the obtained flow results are presente

A search for rotating radio transients and fast radio bursts in the Parkes high-latitude pulsar survey

Discoveries of rotating radio transients and fast radio bursts (FRBs) in pulsar surveys suggest that more of such transient sources await discovery in archival data sets. Here we report on a single-pulse search for dispersed radio bursts over a wide range of Galactic latitudes (|b| < $60^{\circ}$) in data previously searched for periodic sources by Burgay et al. We re-detected 20 of the 42 pulsars reported by Burgay et al. and one rotating radio transient reported by Burke-Spolaor. No FRBs were discovered in this survey. Taking into account this result, and other recent surveys at Parkes, we corrected for detection sensitivities based on the search software used in the analyses and the different backends used in these surveys and find that the all-sky FRB event rate for sources with a fluence above 4.0 Jy ms at 1.4 GHz to be ${\cal R} = 4.4^{+5.2}_{-3.1} \times 10^3$ FRBs day$^{-1}$ sky$^{-1}$, where the uncertainties represent a $99\%$ confidence interval. While this rate is lower than inferred from previous studies, as we demonstrate, this combined event rate is consistent with the results of all systematic FRB searches at Parkes to date and does not require the need to postulate a dearth of FRBs at intermediate latitudes.Comment: Accepted, 10 pages, 6 figure