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Design Optimization of a Diffuser Pump Stage by 4 points in Efficiency

In this project, the client asked ADT to perform a hydrodynamic design optimization of a strongly interacting diffuser pump stage using the inverse design code TURBOdesign1. The focus of the design was to minimize the hydrodynamic loss generation, particularly in the diffuser channels. Figure 1 below shows the pump diffuser arrangement.

The project was divided into several tasks. Initially, a detailed flow analysis of the existing pump diffuser was performed. Due to the strong interaction between the impeller and the diffuser blade rows, ADT performed a full stage unsteady flow analysis in order to understand the flow structure and loss generation mechanism in the machine.

diffuser-pump-stage-design

Based on the analysis study, the majority of loss generation occurred in the diffuser channel. A redesign of the impeller blades was performed using TURBOdesign1 to minimize the secondary flow losses in the impeller and reach an uniform flow condition at the impeller exit and diffuser inlet. Unsteady flow analysis confirmed that the new impeller had a higher efficiency and also resulted in more circumstantially and axially uniform exit flow distribution.

The diffuser redesign was followed by prescribing a modified thickness and loading distribution in the inverse design code TURBOdesign1 so that an optimised flow in the diffuser channel was obtained. Unsteady flow analysis in the pump stage was then performed using the redesigned impeller and diffuser blades.

The results showed up to 4 points improvement in stage efficiency was obtained in the redesign configuration. Flow details comparison show an optimised flow field in the diffuser, see Fig. 2 and 3.

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About Advanced Design Technology

We provide software and services for the design and optimization of turbomachinery, based on our unique 3D Inverse Design technology. Our tools and services help customers achieve innovative “breakthrough” designs, delivering market leading solutions at dramatically reduced development costs.

ADT, headquartered in London, UK, was established in 1999 as a joint venture between University College London and The Ebara Research Co Limited of Japan. We are considered as one of the leading global turbomachinery design software providers, with our TURBOdesign Suite tool set in use across a very wide range of applications and sectors. 

Our design consultancy services deliver cutting-edge solutions to our global customers. Whether the task involves a complete solution, from concept to final design for manufacturing, or is facing challenging multi-point / multi-objective design optimization, we work closely with our customers and support them throughout the entire design process.

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