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Area of Science:

  • Fluid Mechanics
  • Aerodynamics
  • Mechanical Engineering

Background:

  • Multistage centrifugal compressors are critical in various industries.
  • Return channels significantly influence compressor performance.
  • Optimizing return channel geometry is key to enhancing efficiency.

Purpose of the Study:

  • To numerically investigate the effect of return channel design parameters on multistage centrifugal compressor performance.
  • To optimize the return channel shape using a multiobjective genetic algorithm.
  • To experimentally validate the performance improvements of the optimized design.

Main Methods:

  • Numerical investigation of return channel design parameters.
  • Multiobjective optimization using a genetic algorithm.
  • Sensitivity analysis using Latin hypercube sampling.
  • Experimental performance tests on a two-stage compressor apparatus.

Main Results:

  • Sensitivity analysis identified key parameters: area ratio, radius ratio, and number of vanes.
  • Optimization increased the number of vanes to 22, decreased area ratio to 0.66, and radius ratio to 2.0.
  • The optimized design exhibited more uniform exit flow, leading to a 0.7% increase in overall efficiency and 1.5% in pressure coefficient.

Conclusions:

  • The optimized return channel design significantly improved multistage centrifugal compressor performance.
  • Increased flow uniformity and reduced residual swirl were the primary drivers of performance gains.
  • Numerical and experimental results confirm the effectiveness of the optimization approach.