3D CFD-simulations of a centrifugal research pump in single-and two-phase flow conditions with closed and semi-open impeller are performed. In single-phase flow, a satisfactory agreement to experimental data in terms of head prediction is obtained. For two-phase flows, an Eulerian-Eulerian monodisperse model in combination with a statistical turbulence model is used. A grid dependency is unavoidable for large bubbles since a bubble diameter exceeding the grid scale limits a further refinement of finite volume grid cells. The air bubble diameter is a key parameter for pump performance calculation, which can be shown by a bubble size variation, in which the experimental pump head is captured qualitatively well. Further studies will focus on the improvement of the two-phase model to allow simulations of dense disperse phase and bubble sizes larger than the grid scale. Enabling polydispersity and bubble interaction are assumed to be essential for quantitative pump head prediction.
An assessment of a two-fluid model assuming a continuous liquid and a dispersed gas phase for 3D computational fluid dynamics (CFD) simulations of gas/liquid flow in a centrifugal research pump is performed. A monodisperse two-fluid model, in conjunction with a statistical eddy-viscosity turbulence model, is utilized. By a comprehensive measurement database, a thorough assessment of model inaccuracies is enabled. The results on a horizontal diffuser flow reveal that the turbulence model is one main limitation of simulation accuracy for gas/liquid flows. Regarding pump flows, distinctions of single-phase and two-phase flow in a closed and semi-open impeller are figured out. Even single-phase flow simulations reveal challenging requirements on a high spatial resolution, e.g., of the rounded blade trailing edge and the tip clearance gap flow. In two-phase pump operation, gas accumulations lead to coherent gas pockets that are predicted partly at wrong locations within the blade channel. At best, a qualitative prediction of gas accumulations and the head drop towards increasing inlet gas volume fractions (IGVF) can be obtained. One main limitation of two-fluid methods for pump flow is figured out in terms of the violation of the dilute, disperse phase assumption due to locally high disperse phase loading within coherent gas accumulations. In these circumstances, bubble population models do not appear beneficial compared to a monodisperse bubble distribution. Volume-of-Fluid (VOF) methods may be utilized to capture the phase interface at large accumulated gas cavities, requiring a high spatial resolution. Thus, a hybrid model, i.e., a dispersed phase two-fluid model including polydispersity for flow regions with a dilute gas phase, should be combined with an interphase capturing model, e.g., in terms of VOF. This hybrid model, together with scale-resolving turbulence models, seems to be indispensable for a quantitative two-phase pump performance prediction.
Three-dimensional (3D) unsteady Reynolds-averaged Navier–Stokes (URANS) flow simulations are conducted to investigate the highly unsteady flow field at part load operation of a centrifugal pump. By the availability of unsteady flow field measurement data in the impeller wake region, a thorough validation of the simulation method is performed. Grid independence of the results is ensured. Unsteady characteristics in terms of head and shaft power as well as transient blade loads are evaluated to assess the unsteady pump performance. Significant mis-loading of the blading is revealed when one blade passes the volute tongue and associated with the strong unsteady and 3D flow field in the impeller-volute tongue region. Negative radial velocity in the tongue region is the origin of a vortex at the blade pressure side and a subsequent pressure drop that leads to even temporally negative blade loading. The results provide a detailed insight in the complex part load flow field that might be utilized for an improved pump design. As a valuable secondary outcome, a comparison of results obtained by two widely used computational fluid dynamics (CFD) codes for pump flow simulation is provided, i.e., the commercial code ansyscfx and the branch foam-extend of the open source software openfoam. It is found that the results of both methods in terms of unsteady characteristics as well as local ensemble-averaged velocity field are consistent.
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