Industrial Compressors, Expanders & Turbochargers

Industrial compressors and expanders (typically, a type of turbine used for energy recovery) play an important role in a range of industries, such as chemical process, oil and gas, HVAC, and industrial gas production. Turbochargers are used in transportation and energy production to improve overall engine performance. Turbochargers, industrial compressors and expanders consist of a compressor and a turbine; similar engineering tools are used in design and analysis of all these.

Detailed analyses of the fluid flow and the temperature in the solid

Courtesy Borg Warner Turbo & Emissions Systems.

As organizations strive to meet increasingly stringent customer requirements related to compressors, expanders and turbochargers, they can benefit greatly from the wide range of engineering simulation tools that ANSYS offers.

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Compressors Compressors

Organizations that develop compressors strive to improve efficiency and reliability in a very competitive marketplace, so time to market is a significant consideration. Industrial equipment is usually derived from a standard line of machines. But in many cases — particularly larger machines — the equipment requires some level of customization to meet unique installation or operating requirements. Existing machines may require changes to process, flow rates, gas composition or required operating range. These modifications are usually scheduled on a tight timeline to meet a planned system shut-down schedule. The use of rapid, reliable and high-fidelity design tools is vital to meeting customer schedule and expectation.

ANSYS CFX predicted static pressure distribution on the rotor blades of a centrifugal compressor stage

Expanders Expanders

Expanders typically are used to capture process energy that otherwise would be wasted. The captured energy then is used to drive equipment or produce power. Expanders share many of the same development demands as compressors. Particular challenges relate to erosion caused by particles in the gas stream and complex thermodynamics, in cryogenic applications for example.

Turbochargers Turbochargers

The use of turbochargers for gas and diesel engines is growing rapidly as demand for reduced energy consumption and emissions intensify. Turbochargers traditionally have been employed on large reciprocating engines and used for ship, locomotive, heavy truck, power production and mechanical drive applications. More and more, automotive manufacturers use turbochargers to improve efficiency and derive greater power from small engines. Small turbochargers use a radial inflow turbine to drive a centrifugal compressor; larger units use an axial flow turbine. In all cases, the objective is to improve efficiency and reliability over a very wide operating range. Package size is often a key constraint, particularly for automotive usage.

Blade Geometry Blade Geometry

ANSYS BladeModeler provides tools for the detailed geometric specification of all stationary and rotating bladed components. These tools can be used within the ANSYS Workbench environment or connected into an existing design system, enabling high-productivity design and analysis, including optimization.

Closeup of the maximum principal stress on the pressure side of the redesigned blade

Courtesy Power Systems Manufacturing.

Meshing Meshing

General-purpose and specialized tools from ANSYS enable rapid development of high-quality meshes required by turbomachinery analysts. ANSYS TurboGrid is the tool of choice for optimal high-quality hexahedral blade row meshes that are scalable, consistent, repeatable and automatically generated. 

Throughflow Solver Throughflow Solver

The ANSYS throughflow solver ANSYS VISTA TF is ideal for rapid and reliable single and multi-blade row component design and optimization. A wide selection of models and access to the same post-processing as full ANSYS CFD technology ensures wide applicability and high-productivity usage.

Rotordynamics Rotordynamics

The rotordynamics capability is a central element in the ANSYS structural solver. Availability of axisymmetric as well as full 3-D element types enables a scalable modeling approach adaptable to any situation, offering the ability to include not only seal and bearing effects but casing influence as well.  

Automated Turbo Pre- & Post-Processing Automated Turbo Pre- & Post-Processing

Turbomachinery blade row-specific pre- and post-processing tools simplify the process and reduce overall simulation time. All general and turbomachinery-specific functions are available in a modern graphical user interface or via command, ideal for repeatable, automated operation.