Dynamic compressors are employed to provide a pressurized flow of fluid for various applications.
The Detailed Description is described with reference to the accompanying figures. The use of the same reference numbers in different instances in the description and the figures may indicate similar or identical items.
Referring generally to
In some embodiments, a dynamic compressor 100 can be configured as a centrifugal compressor 102 that provides a pressurized flow of fluid. The centrifugal compressor 102 includes an impeller 104 configured to receive a fluid flow 106, accelerate the fluid flow 106 to a higher velocity, and then dispense the high velocity fluid flow 106. For instance, the impeller 104 includes multiple blades 108 configured to rotate about an axis 110 to receive a fluid flow 106 at least substantially aligned with the axis 110. The impeller 104 can be driven by an electric motor, an internal combustion engine, or another drive unit configured to provide rotational output. In the present example, the impeller 104 accelerates the fluid flow 106 to a higher velocity, and then dispenses the high velocity fluid flow 106 in a direction at least generally perpendicular to the axis 110 (e.g., radially with respect to the axis 110).
The centrifugal compressor 102 also includes a diffuser 112 in fluid communication with the impeller 104. For example, the diffuser 112 is circumferentially disposed around the impeller 104. The diffuser 112 is configured to receive the high velocity fluid flow 106 from the impeller 104 and convert the high velocity fluid flow 106 into a high pressure fluid flow 106. In this manner, the centrifugal compressor 102 produces a high pressure fluid output. In some embodiments, the diffuser 112 may include a series of vanes 114 and/or vanelets. The centrifugal compressor 102 further includes a discharge collector 116 in fluid communication with the diffuser 112. The discharge collector 116 receives the high pressure fluid flow 106 from the diffuser 112 and discharges the high pressure fluid flow 106 from the centrifugal compressor 102. The discharge collector 116 includes a scroll or volute 118 and may include a shroud (not shown) but is not limited to this configuration.
In embodiments of the disclosure, the centrifugal compressor 102 includes an inlet 120 in fluid communication with the impeller 104. The inlet 120 supplies the fluid flow 106 to the impeller 104. The inlet 120 includes a nozzle inlet 122, a nozzle outlet 124, and an exponential cross-sectional profile 126. As described herein, the exponential cross-sectional profile 126 of the inlet 120 is configured to control the fluid flow 106 into the impeller 104 to provide a highly uniform flow distribution at the nozzle outlet 124 of the inlet 120. For instance, the inlet 120 is configured to collect fluid flow (e.g., from an inter-stage cooler or from upstream processes) and then deliver uniform and axisymmetric flow to an inducer section of the impeller 104. It should be noted that the centrifugal compressor 102 is provided by way of example and is not meant to limit the present disclosure. In other embodiments, an inlet 120 as described herein may be used with other various compressors and other dynamic fluid machines or turbomachines, including, but not necessarily limited to axial compressors, turbines, pumps, and so forth.
Generally, compressor efficiency is a function of the inlet, impeller, diffuser, and scroll/volute performance, as well as the interaction between these components. A major problem of centrifugal compressor design and development is flow non-uniformity at the exit of flow conditioning devices at the inlet of the centrifugal stages. Axisymmetric inlet nozzles may use circular arc shapes, elliptical quadrant shapes, or Witoszynski profile shapes. These nozzles perform well in subsonic flows when certain design parameters are met. However, when centrifugal compressors are subject to severe space constraints, these flow devices operate far from the intended parameters. For example, some designs are based upon a nozzle area ratio (i.e., the ratio between the nozzle inlet area and the nozzle outlet area) that is relatively high, exceeding, for example, about fifteen (15). Another condition is that the nozzle aspect ratio (i.e., the ratio between the nozzle axial length and the nozzle radial contraction) is between about two and one-tenth (2.1) to about two and one-half (2.5), with the major axis aligned with the main flow. The first condition implies that the flow entering the nozzle is almost stagnant, and the kinetic energy of the flow is very low. The gas flow then goes through the nozzle and accelerates, thus partially converting potential energy into kinetic energy.
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In some embodiments, β may be between at least approximately one (1) and at least approximately five (5). For example, β can be between at least approximately two and one-tenth (2.1) and at least approximately two and one-half (2.5). However, it should be noted that these values are provided by way of example and are not meant to limit the present disclosure. In other example, values for β less than about one (1) or greater than about five (5) can also be used.
The effectiveness of the inlet 120 as a flow conditioning device heavily impacts the overall aerodynamic performance of the centrifugal stage of the compressor. For a design to yield high aerodynamic efficiencies, ideal flow conditions should be met. As mentioned previously, ideally, the flow at the entrance of the impeller is irrotational, axisymmetric, and uniform in both radial and circumferential directions. Additionally, the turbulent boundary layer at the entrance of the inducer section of the impeller is as thin as possible. As described herein, the inlet 200 has an exponential cross-sectional profile 212 that serves as the final component of an inlet assembly and completes the flow conditioning process as the fluid flow 206 enters the impeller section of the centrifugal compressor stage. In some embodiments, the shape of the inlet nozzle contour can be adjusted to attain a desired level of cross-sectional flow uniformity.
The exponential cross-sectional profile 212 of the inlet 200 is defined by the following equation:
where r1 is the nozzle inlet radius, r2 is the nozzle outlet radius, L is the total length of the nozzle, ξ is an axial coordinate with origins at the nozzle inlet, and α is an exponential shape constant. The control parameter, an exponential factor of α, governs the contour shape of the exponential cross-sectional profile 212, thus facilitating a controlled flow acceleration within the inlet 120 to achieve a desired flow pattern at the nozzle outlet 210. The equation is a smooth, continuous, and differentiable function uniquely defined within [r1, r2] limits, where r=r1 when ξ=0, and r=r2 when ξ=L. The first order derivative at the nozzle inlet 208 is given by the following equation:
The first order derivative at the nozzle outlet 210 is given by the following equation:
As inferred from the equation at the nozzle inlet 208, the first order derivative at the nozzle inlet 208 becomes unbounded when parameter α approaches infinity. For this reason, the tangent to the exponential curve is orthogonal to the axis of rotation z. When parameter α approaches infinity at the nozzle outlet 210, the slope to the exponential curve becomes a horizontal line.
When selecting α-parameters between about three (3) and about twenty (20), e.g., about five (5), about five and one-half (5.5), about six (6), about six and one-half (6.5), about seven (7), fluid transitions seamlessly from the nozzle outlet 210 into either a cylindrical section preceding the impeller or directly to the shroud surface. These α-parameters result in a virtually horizontal tangent line at the nozzle outlet 210, e.g., because the first-order derivatives of their respective functions are very small. Meanwhile, the first order derivatives at the nozzle inlet 208 are large; thus, their tangent lines can be almost orthogonal to the axis of revolution z.
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The exponential inlets 200 initiate flow restructuring earlier than the other nozzles, e.g., by generating higher loadings within the entrance section of the inlets. Since the flow velocities are lower at the nozzle inlet area than further downstream, the flow redistribution penalties in the exponential inlets 200 are lower than in the other nozzles, where the flow restructuring occurs in the downstream parts of the nozzles. For the pre-loaded inlets 200, additional losses are incurred in the downstream section of the inlets where the pre-accelerated flow is left to complete its development, and the velocities are higher than in the elliptical and Witoszynski nozzles. It is noted that the formation of turbulent boundary layers in the downstream section of the exponential inlets 200 may be controlled by the selection of α; thus, boundary layer displacement thicknesses may be only marginally higher than the corresponding values for the elliptical and Witoszynski nozzles.
In these examples, the Witoszynski nozzle is the flow conditioning device with the smallest values of aerodynamic losses, especially for the higher area ratios where the cross-flow distribution is extremely uniform at the nozzle outlet. For the lower area ratio nozzles, which are found in centrifugal compression applications, the Witoszynski nozzles are not sufficiently aggressive to force flow restructuring within severely constrained spaces. Thus, the flow may not be redistributed to yield the desired characteristics at the nozzle outlet. In these instances, further flow conditioning may be necessary. The elliptical nozzles exhibit more aggressive load distribution than the Witoszynski nozzles, which is skewed towards the nozzle inlet section. By forcing the flow redistribution in the early sections of the nozzles, more favorable results at the nozzle outlet albeit may be obtained, but this may be at the expense of higher aerodynamic losses across the nozzle. Provided the losses are no higher than marginal, there a tradeoff can be made between delivering a uniform flow distribution at the nozzle outlet and incurring additional losses. For example, elliptical nozzles are more efficient than the Witoszynski nozzles for centrifugal compression applications with severe spatial constraints.
The exponential inlets 200 of the present disclosure further accelerate the flow redistribution in the inlet sections of the flow conditioning devices. Since the slopes of the exponential inlets 200 can readily be adjusted by the shape parameter α, the aerodynamic loadings can be controlled to yield superior performance from the nozzles. For instance, a decrease of the α-parameter results in more moderate loadings, while an increase leads to more aggressive loadings. Thus, depending on the implementation, the value of α may be easily adjusted to yield sufficiently uniform flow profiles at the nozzle outlet 210, while maintaining aerodynamics losses within acceptable levels. This flexibility allows customization of the exponential nozzle geometry to achieve a desired level of flow uniformity at the nozzle outlet 210, while maintaining the aerodynamic losses at marginal levels. This beneficial tradeoff between flow uniformity and total accumulated losses may be implemented for a wide range of design parameters for various centrifugal compressors, such as the centrifugal compressor 102.
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This equation was generalized based on hundreds of computational fluid dynamics (CFD) analyses and provides a concise pathway for exponential-shaped nozzles to attain extremely uniform flow conditions at the nozzle outlets while maintaining negligible aerodynamic losses across the flow conditioning units. It should be noted that the generalization for the critical value of the α-parameter may be unique and invariant to the Mach number.
It will be appreciated that while dynamic fluid machines or turbomachines have been described with some specificity herein, the apparatus, systems, and techniques of the present disclosure may be also be applied to other devices where high flow uniformity at a nozzle outlet is desirable, including, but not necessarily limited to, precise flow measurement devices and the like.
Although the subject matter has been described in language specific to structural features and/or process operations, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.