Numerical simulation of stall development into surge and stall control using air injection in centrifugal compressors

Abstract

This study presents a numerical simulation of the formation of rotating stall and the initiation of surge in order to study the connection between stall and surge in centrifugal compressors. Also, the current paper introduces an optimization of the air injection method as a way to increase the surge margin. Results showed that during stall, the compressor is exposed to velocity and pressure fluctuations varying with time, and these fluctuations are increased suddenly and causing surge initiation. The major part which is responsible for the sudden increase in fluctuations is the vaneless region because it was found that the problem starts at the impeller exit near the shroud surface and then transfers to the impeller inlet. Results also showed that during surge, forces on the impeller blades increase to nearly double of its initial value and then decrease again. By using air injection at the vaneless region with different injection angles, it was found that injection with angle of 30° has a good effect on preventing surge and minimizing the pressure fluctuations comparing to other injection angles results. Results showed finally that the surge margin can be increased by using the injection with angle of 30° and with injection mass flow rate of 1% of the design inlet mass flow rate and this causes the surge limit to shift from 4 kg/s to 3.9 kg/s.