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Research Papers

Simulation of Particle Trajectories and Erosion in a Centrifugal Compressor

[+] Author and Article Information
Adel Ghenaiet

Laboratory of Thermal Power Systems, Applied Mechanics, EMP, BP17, Bordj El Bahri 16111, Algiers, Algeriaag1964@yahoo.com

J. Turbomach 134(5), 051022 (May 11, 2012) (19 pages) doi:10.1115/1.4004448 History: Received April 04, 2011; Revised April 22, 2011; Published May 11, 2012; Online May 11, 2012

Turbocompressors manipulating particle-laden airflows suffer from severe erosion damages which affect their operating performance and lifetime. This paper presents the results of a numerical investigation of the dynamics of sand particles and the subsequent erosion in a centrifugal compressor. The particle trajectories simulations used a developed code based on a stochastic Lagrangian model, which solves the equations of motion separately from the airflow, whereas the tracking of particles in different computational cells used the finite element method. The number of particles, sizes, and initial positions were specified, conformed to a sand particle size distribution AC_coarse (0–200 μm), and a given concentration profile. The obtained results show that the speed of rotation and particle size strongly affect the trajectories of particles and their locations of impact. Erosion is spreading over the pressure side of the main blade. Regions of high erosion rates are seen over the leading edge, at the inducer top corner and along the blade tip. Over the splitter pressure side erosion wear is much less than the main blade. The suction sides are almost without erosion except near the leading edge, and the casing is mainly affected over the inducer and tips of the blades.

Copyright © 2012 by American Society of Mechanical Engineers
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Figures

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Figure 14

Sample of particle trajectories (size: 50 μm), compressor operating at 60,000 rpm: (a) at intake, (b) side view, and (c) top view

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Figure 15

Sample of impacts due to sand particles (size: 50 μm), compressor operating at 60,000 rpm: (a) impact velocities (m/s), (b) impact angles (°), (c) local erosion rates (mg/g)

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Figure 16

Sample of particles trajectories (size: 10 μm), compressor operating at 60,000 rpm: (a) at intake, (b) side view, and (c) top view

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Figure 17

Sample of impacts due to sand particles (size: 10 μm), compressor operating at 60,000 rpm: (a) impact velocities (m/s), (b) impact angles (°), and (c) local erosion rates (mg/g)

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Figure 20

Equivalent erosion rates (mm3 /g/mm2 ) due to sand (AC-coarse 0-200 μm) ingestion at a concentration of 300 mg/m3 , compressor operating at 40,000 rpm: (a) main blade, (b) splitter, (c) impeller hub, (d) impeller shroud, (e) diffuser hub, and (f) diffuser shroud

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Figure 21

Equivalent erosion rates (mm3 /g/mm2 ) due to sand (AC-coarse 0-200 μm) ingestion at a concentration of 300 mg/m3 , compressor operating at 60,000 rpm: (a) main blade, (b) splitter, (c) impeller hub, (d) impeller shroud, (e) diffuser hub, and (f) diffuser shroud

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Figure 22

Equivalent erosion rates (mm3 /g/mm2 ) due to sand (AC-coarse 0-200 μm) ingestion at a concentration of 300 mg/m3 , compressor operating at 80,000 rpm: (a) main blade, (b) splitter, (c) impeller hub, (d) impeller shroud, (e) diffuser hub, and (f) diffuser shroud

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Figure 1

Turbocharger Schwitzer

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Figure 11

(a) Flow velocity vectors in meridional hub to shroud plane, (b) Relative Mach number in meridional hub to shroud plane

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Figure 12

Sample of particle trajectories (size: 200 μm), compressor operating at 60,000 rpm: (a) at intake, (b) side view, and (c) top view

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Figure 13

Sample of impacts due to sand particles (size: 200 μm), compressor operating at 60,000 rpm: (a) impact velocities (m/s), (b) impact angles (°), and (c) local erosion rates (mg/g)

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Figure 18

Sample of particle trajectories of sizes AC-coarse (0-200 μm), compressor operating at 60,000 rpm: (a) side view, and (b) top view

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Figure 19

Sample of impacts due to sand particles of sizes AC-coarse (0-200 μm), compressor operating at 60,000 rpm: (a) sizes of impacting particles (μm), (b) impact velocities (m/s), (c) impact angles (°), and (d) local erosion rates (mg/g)

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Figure 2

CAD geometry of compressor parts: (a) impeller side view, (b) vaneless diffuser and scroll

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Figure 3

Computational domains

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Figure 4

Computational grids: (a) hub to shroud grids, and (b) mid-span grids

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Figure 5

Compressor aerodynamic performance: (a) pressure ratio, and (b) total-to-total isentropic efficiency

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Figure 6

Relative flow velocity vectors through intake, impeller, and diffuser: (a) mid-span, and (b) tip clearance

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Figure 7

Static pressure through intake, impeller, and diffuser: (a) mid-span, and (b) tip clearance

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Figure 8

Relative Mach number through intake, impeller, and diffuser: (a) mid-span, and (b) tip clearance

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Figure 9

Flow velocity vectors at different impeller passage cross sections

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Figure 10

Relative Mach number at different impeller passage cross sections

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Figure 25

Eroded blade tip profile due to sand concentration of 300 mg/m3 , compressor operating at 100,000 rpm

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Figure 23

Equivalent erosion rates (mm3 /g/mm2 ) due to sand (AC-coarse 0-200 μm) ingestion at a concentration of 300 mg/m3 , compressor operating at 100,000 rpm: (a) main blade, (b) splitter, (c) impeller hub, (d) impeller shroud, (e) diffuser hub, and (f) diffuser shroud

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Figure 24

Eroded blade tip profile due to sand concentration of 300 mg/m3 , compressor operating at 60,000 rpm

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Figure 26

Erosion of main blade of impeller after 1 h of sand ingestion (AC-coarse, 0-200 μm) with different operating speeds

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Figure 27

Erosion of splitter after 1 h of sand ingestion (AC-coarse, 0-200 μm) with different operating speeds

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Figure 28

Blade geometry deterioration after 1 h of sand ingestion (AC-coarse, 0-200 μm) with different operating speeds

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Figure 29

Erosion of impeller hub and shroud after 1 h of sand ingestion (AC-coarse, 0-200 μm) with different operating speeds

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Figure 30

Erosion of vaneless diffuser after 1 h of sand ingestion (AC-coarse, 0-200 μm) with different operating speeds

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Figure 31

Eroded impeller photographs, adapted from Tabakoff and Hamed [25]

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