Beruflich Dokumente
Kultur Dokumente
net/publication/327871385
CITATIONS READS
0 14
1 author:
Ahmed Kovacevic
City, University of London
157 PUBLICATIONS 812 CITATIONS
SEE PROFILE
Some of the authors of this publication are also working on these related projects:
All content following this page was uploaded by Ahmed Kovacevic on 25 September 2018.
25/09/2018 2
Agenda
Introduction
■ 3D CFD modelling of screw machines
■ Test cases
Future
Thanks to:
EPSRC, Howden, Trane, UTRC, Goodrich, Kobelco,
PDM Analysis Ltd, Simerics, Star-CCM+, CFX Berlin, VertRotors,
for support in developing CFD in PD screw machines and software SCORG.
25/09/2018 3
Kosaka lab
Flowserve Bornemann
Vert Rotor
Howden
Vilter
Screw Compressors Today
83% Oil injected ; 17% Oil free
• Applications:
Industrial and commercial
Air compression, Refrigeration,
Process gasses Oil & Gas,
Expanders, multiphase
• Dia (35) 50 – 1000 mm
• 0.3 – >1000 m3/min
• 0.5 kW – 5 MW
• High Efficiency, Reliable
80% of new industrial compressors are screw compressors Large Packages ~800
17% energy produced in developed countries used for compression
25% energy in USA during summer is used for refrigeration and air-conditioning
Trends
25/09/2018 6
Global screw compressor sales $7.99 billion in 2016
$3.15 b
$2.53 8.05%
7.65
%
$1.76b
6.07%
$2.25 b
4.82%
$1.32 b
3.21%
7
The oil-free segment is expected to grow at the highest CAGR from 2016 to 2021
Compressors and energy
■ Compressors consume more than 17% energy produced in developed
countries. This pollutes the environment with more than 3000 MtCO2
per year, while energy costs exceed €275 billion per year*.
■ The global CO2 emission will increase by up 28% from 2015 to 2030,
■ The latest EU targets for 2020 are to reduce the CO2 emissions by 20%
from the levels recorded in 1990. This requires:
• 20% of energy produced by renewable sources
• increase energy efficiency by 20% from the levels recorded in 2007.
currently these targets may not be achieved despite efforts by both
industry and academia.
■ Oil injected compressors and other multiphase fluid handling machines
have great potential for improvements in efficiency and contributing to
reduction in CO2 emission.
*Source: http://www.iea.org/publications/freepublications/publication/EE_for_ElectricSystems.pdf
3rd Short Course/Forum on
CFD in Positive displacement rotary machines
9th – 10th September 2017
Previous events:
2007;
2013; 2015, 2017
Next event
2019
25/09/2018
25/09/2018 10
Test cases used in this presentation:
Oil free Screw Compressor - XK18 3/5 ‘N’ Profile, CD 93
– Main Rotor OD, 127.446mm
– Gate Rotor OD, 120.380mm
– L/D Ratio, 1.6
– Wrap Angle, 280º
– Built in Vi, 1.8
– Clearances: • Interlobe 170 µm
• Radial 160µm
• End Axial 160µm
25/09/2018 11
Agenda
Introduction
■ 3D CFD modelling of screw machines
■ Test cases
Future
25/09/2018 12
Mathematical models for calculation of
positive displacement screw machines
Differential methods based on continuum principles (macroscopic)
A. Thermodynamic chamber model:
Simple(r), many assumptions made, fast, limited accuracy
B. 3D Computational Fluid Dynamics (CFD) model
Complex, fewer assumptions, slow(er), gives more detail
C. Integrated models:
Not as complex as 3D but more accurate than Chamber model
d
∫
dt V
ρφ dV + ∫ ρφ ( v − v b ) ⋅ ds =Γ
S
∫
S
φ grad φ ⋅ ds + ∫ qφ S ⋅ ds + ∫ qφV ⋅ dV
S V
Thermodynamic Multi Chamber Modelling
Numerical solution: Conservation of mass and energy dm
• Any working fluid - Ideal or real, ω = m in − m out
• Includes fluid to solid heat transfer dθ
dU dV
• Independent on a machine geometry ω = m in hin − m out hout + Q − ω p
• Liquid injection modelled (multiphase) d θ dθ
Limitations: Same
• Fluid flow is assumed “quasi” one-dimensional principle
• Kinetic energy is neglected for energy
• Assumed isentropic flow through inlet and outlet ports
• Assumed adiabatic flow through clearances pV = zmRT
• Tuning required for specific machines
25/09/2018 15
3D CFD modelling based on continuity principles
d
∫
dt V
ρφ dV + ∫ ρφ ( v − v b ) ⋅ ds =Γ
S
∫
S
φ grad φ ⋅ ds + ∫ qφ S ⋅ ds + ∫ qφV ⋅ dV
S V
Navier-Stokes
φ Γφ qfS qfV
Continuity 1 0 0 0
Key Elements
• 3D Transient,
• Turbulence,
• Grid Generation,
• Moving / Deforming Boundaries,
• Compressible Fluids,
• Multiphase / Oil Injection
25/09/2018 17
Solution domain and grid generation
25/09/2018 18
Grid generation approaches
• Grid systems
- structured
body fitted,
cut Cartesian
- unstructured
- mixed
• Block structured
- overlapping
- discontinuous
- continuous
- conformal
Skewness factor gives more information about grid than other quality measures
25/09/2018 20
Agenda
Introduction
■ 3D CFD modelling of screw machines - Issues
■ Test cases
Future
25/09/2018 21
Issues - Requirements
Phenomenological
• Multi-Phase fluids
• Fluid-Solid Interaction
25/09/2018 22
Numerical
Issue 1
Conservativeness
Mesh topology
from J. Vierendeels, Ghent University, Introduction to CFD in PD machines, Short Course, London, Sep 2015
Case Study Piston-Cylinder Analysis
■ Reversible Adiabatic Compression-Expansion Process
■ Mesh Smoothing and Key-Frame re-meshing methods compared with
the theoretical results
25/09/2018 24
Numerical
Piston-Cylinder Analysis
𝛾𝛾
𝑝𝑝2 𝑉𝑉1 𝛾𝛾 𝑇𝑇2 (𝛾𝛾−1)
� � =� � =� �
𝑝𝑝1 𝑉𝑉2 𝑇𝑇1
Issue 1
Conservativeness
Mesh topology
Diffusion Equation Mesh Smoothing is more accurate then Key Frame Remeshing
25/09/2018 25
Numerical
Time discretisation:
• Explicit forward Euler - 1st Order
• Implicit backward Euler - 1st Order Issue 2
• Implicit 2nd order backward - 2nd order Discretisation and
• Explicit Multi-stage (Runge Kutta) – higher order solution method
Speed and
Space discretisation: accuracy of a
• 1st order forward differencing solver
• 1st order backward differencing
• 2nd order central differencing
• 2nd order backward differencing
25/09/2018 26
Numerical - practical
25/09/2018 27
Numerical - practical
Representing the mesh in the solver
CFX
Other solvers
25/09/2018 28
Performance comparison - Oil free compressor
Advection Scheme High Resolution Upwind 2nd Order Upwind 2nd Order Upwind
Turbulence Scheme First Order Upwind First order upwind First Order Upwind
Rotor mesh size male/female 292320/290000 Total=582320 rotor cells (medium coarse mesh)
25/09/2018 29
Numerical - practical
12.0
11.0
10.0
9.0
8.0
7.0
6.0
5500 6000 6500 7000 7500 8000 8500
25/09/2018 31
Solvers Formulation Turbulence Model
Analytical Mass Flow Rate: Solver–1 gives ~ 7% higher leakage Product of average Velocity
• Steady, 1D isentropic flow through flow under same operating conditions. and Density at the throat area
a Converging-Diverging Nozzle
v_avg ρ_avg vρ % Diff
• choked flow
• Mass flow rate depends only Solver-1 270.57 1.636 442.7 Reference
on the upstream density Solver-2 291.51 1.386 403.9 8.77
Solver-3 244.83 1.641 401.7 9.26
Solver-4 244.83 1.641 401.7 9.26
Solver-5 308.21 1.305 402.2 9.16
Solver-6 293.33 1.425 418.0 5.58
25/09/2018 32
Results plotted for k-epsilon turbulence model
Numerical
Issue 3
Mesh Orientation
Numerical
Diffusion
25/09/2018 33
from J. Vierendeels, Ghent University, Introduction to CFD in PD machines, 3rd Short Course, London, Sep 2017
25/09/2018 34
from J. Vierendeels, Ghent University, Introduction to CFD in PD machines, 3rd Short Course, London, Sep 2017
Issue 3
Alignment of the
flow and the grid
Accuracy
25/09/2018 35
from J. Vierendeels, Ghent University, Introduction to CFD in PD machines, 3rd Short Course, London, Sep 2017
Numerical - practical
Definition of Solve
Definition of
Interphase Conservation
phases
Interactions PDE’s
25/09/2018 36
Agenda
Introduction
■ 3D CFD modelling of screw machines
■ Test cases
Future
25/09/2018 37
Geometrical Inputs
Grid generation for
Boundary Distribution Inputs
Meshing Inputs reliable 3D CFD
How we do it!
Generation of Rotor Profiles and
Rack as the Parting line
Boundary Discretisation
• Fully conservative
• Grid aligned/not aligned to clearance flow
• Used exclusively with CFX solver
25/09/2018
From Dr. Andreas Spille-Kohoff, Jan Hesse, Rainer Andres, CFX Berlin Software GmbH, Germany 42
presented at 2nd Short Course on CFD in Positive Displacement Machines, London, September 2015
Similar grid generation techniques
• Fully conservative
• Grid not aligned to clearance flow
• Used exclusively with Fluent solver / proprietary to Atlas Copco
From: Iva Papes, Joris Degroote, Jan Vierendeels, University of Gent, Belgium
“New insights in twin screw expander performance for small scale ORC systems from 3D CFD analysis”
25/09/2018 43
https://doi.org/10.1016/j.applthermaleng.2015.08.034
Other grid generation techniques
Structured Cut-Cartesian body fitted
• Not conservative
• Grid not aligned to clearance flow
• Attempted by many users but not suitable for screw
machines
• Computationally very expensive
25/09/2018 From Dr Mohammad Omidyeganeh, City, University of London, UK 45
nd
presented at 2 Short Course on CFD in Positive Displacement Machines, London, September 2015
Other grid generation techniques
Overset meshes:
- No re-meshing
- Expensive interpolation
- Redundant calculation
in some regions of
overlapping meshes
- Very large grids,
impractical and slow
• Not conservative
• Grid not aligned to clearance flow
• Extensive calculation and large mesh
Immersed
Surface
Baseline
Grid
• Not conservative
• Grid not aligned to clearance flow
• Special solvers required
• Not conservative
• Grid not aligned to clearance flow
• Demanding grid generation and special algorithms for calculations
• But first results are available
25/09/2018 48
Agenda
Introduction
■ 3D CFD modelling of screw machines
Future
25/09/2018 49
25/09/2018 50
SCORG to Star-CCM+
C# written
DLL library
SCORG to Ansys-CFX
User Fortran
Library
SCORG to Simerics MP
Direct Link
Multiphase flow
Oil - distribution
(2001)
Multiphase flows
2016
55
Oil Injected low pressure case
(includes end leakage gaps)
High Pressure
End Leakage
gap
56
Oil Injected low pressure case
(includes end leakage gaps)
25/09/2018 60
Conjugate heat transfer using SCORG and Ansys-CFX
2016
61
Air Screw Expander
Internally geared conical screw
Helical Gate Rotor (Internal Lobes)
Suction
Outlet
63
Liquid Screw Pump – Cavitation
SCORG and Star CCM+
64
0.85 MPa Discharge Pressure, 630 rpm 0.85 MPa Discharge Pressure, 2100 rpm
Integrated model (CFD + Thermodynamic)
Integrated
Full 3D CFD
model
model (Comet)
(Star CCM+)
Flow oscillations - Noise suppression
Comparison of different calculation models
To summarise – what we learned so far
■ CFD based on continuity principle is today readily available
to be used in industry for modelling of screw machines
■ Grid generation is critical for analysis of screw machines:
■ Conservativeness
■ Alignment of the flow and numerical mesh
■ Discretisation scheme and selection of a solver
Questions still open to be answered:
■ How can we use models to further reduce leakage losses?
■ How to reduce modelling efforts and improve efficiency of
multiphase machines?
■ How is conjugate heat transfer affecting performance and
reliability and how to use it in improving screw machines?
■ How can we reduce computing time?
■ Are there any better methods than the current ones?
25/09/2018 67
Future work
Initialising solution – faster convergence
Hex cells
are orthogonal
Straight rotor Screw rotor
25/09/2018 69
Future work
Leakage flows, conjugate heat transfer and validation cases
25/09/2018 70
Future work - Lattice Boltzman Method
■ LBM models the fluid consisting of fictive particles, and such
particles perform consecutive propagation and collision
processes over a discrete lattice mesh.
■ Based on Kinetic theory of gases (Microscopic)
■ Uses Mesoscopic scale to solve Boltzman Equation
25/09/2018 71
Future work - Lattice Boltzman method
discretize the differential operator and the collision operator in this form
25/09/2018 72
The 4th Short Course on CFD in Rotary
Days 1 and 2 Positive Displacement Machines
Research and technical papers including 7th - 8th September 2019
keynotes, podium papers and
discussions. • Advances in grid generation, CFD tools and new
techniques for PD machine analysis
Industry Day (Day 3) • Modelling leakage flows and conjugate heat
Representatives from industry discuss transfer
challenges and success in technology or • Prediction of clearance gap sizes during operation
and application of modern FSI computations
market demands, eg. due to economic,
• Stability and accuracy of Multiphase flow
environmental or legislative changes. calculations in PD machines.
25/09/2018 73
Conclusions
■ CFD in screw machines is becoming increasingly popular.