A Casing Treatment with Axial Grooves for Centrifugal Compressors

Abstract

This paper provides an investigation of a casing treatment (CT) approach for pressure ratio improvements of centrifugal compressors between peak efficiency and surge. Results were experimentally verified for a variety of automotive turbocharger compressors and analyzed with 3D CFD. The CT design is an adaptation from an axial high-pressure compressor, which was successfully applied and intensively investigated in recent years. The aerodynamic working principle of the applied CT design and the achievable improvements are shown and described. The demand of operating range for automotive applications typically dictates high inlet shroud to outlet radius ratio (high trim) and past experiences indicate that a recirculation zone is formed in the inducer for those centrifugal compressors. This recirculation at the inlet shroud causes losses, a massive blockage and induces a co-rotating swirl at the inlet of the impeller. The result is a reduced pressure ratio, often leading to flat speed lines between the onset of recirculation and surge. This paper provides an understanding of inducer recirculation, its impacts and suggests countermeasures. The CT design for centrifugal compressors only influences flow locally at the inducer and prevents recirculation. It differs substantially in design and functionality from the classical bleed slot system commonly used to increase operating range. An experimental and CFD comparison between these designs is presented. While the classical bleed slot system often provides a massive increase in operating range, it often fails to increase the pressure ratio between onset of inducer recirculation and surge. In contrast, the CT design achieves a gain in pressure ratio near surge.

Instability Phenomena in Centrifugal Compressors and Strategies to Extend the Operating Range: A Review

“…Leichtfuß et al [114] evaluated axial grooves in different compressor configurations, showing a surge extension, especially for high speeds; it reduced the inlet recirculation and increased the pressure ratio, while the efficiency decreased by 2% due to mixing losses. Cravero and Marsano [115] compared the advantages of the axial groove with those Leichtfuß et al [114] evaluated axial grooves in different compressor configurations, showing a surge extension, especially for high speeds; it reduced the inlet recirculation and increased the pressure ratio, while the efficiency decreased by 2% due to mixing losses. Cravero and Marsano [115] compared the advantages of the axial groove with those of the ported shroud.…”

Investigation of Suction Flow Control on Centrifugal Compressor with Vaned Diffuser

“…The flow was simulated as fully turbulent, and the k-ω Shear Stress Transport (SST) [18] turbulence model was employed. In many studies in the literature [19][20][21][22][23][24][25][26], k-ω SST turbulence model has been used as it can accurately model the separated flow occurring in centrifugal compressors with low computational cost. The total energy model was activated to solve heat transfer in the compressor.…”

A comparison of strategies to extend the operating range of radial compressors for turbocharging

“…The axial groove consists of a similar solution to the previous but more compact: there is a single opening on the inducer shroud where grooves are designed to guide recirculating flow with minimum losses. The benefits of axial grooves has been studied is numerical works [23,24]. Finally, circumferential grooves can be installed at the diffuser to alleviate blockage in vaned diffusers [25,26].…”