Numerical simulation of Thermo-Fluid dynamic entropy generation in centrifugal

compressors for Micro-turbine application

Kittipass Wasinarom1, Dachdanai Boonchauy, and Jaruwat Charoensuk2

Department of Mechanical Engineering, Faculty of Engineering,

King Mongkut's Institute of Technology Ladkrabang,
Bangkok, Thailand 10520
* Corresponding Author: Tel: 0-2329-8351, Fax: 0-2329-8352,
E-mail: [email protected],[email protected]

Abstract
This research proposed for investigation on the quantitative entropy generation in the streamwise location of flow passage of
centrifugal compressors with different exit beta angle. The compressors operating condition is designed for small gas turbine
application. The flow field was obtained by 3D numerical simulation technique (CFD), with the help of commercial CFD code.
The analysis is coupled both of flow structure and quantitative entropy that generation from the compressor inlet to the outlet. The
comparison have been made between 10, 20, 30, 40 and 50 exit beta angle. The simulation result, shows the streamwise location
of 0.1-0.6 entropy generate around 60 J/kg.K per streamwise location length for all exit beta angle, because of the inflow direction
is parallel with the flow passage. In contrast, at the location 0.6-1.0 entropy generate around 480 J/kg.K per streamwise location
length, around 8 times of the entropy generated in location 0.1-0.6. This is correspondent to the high deformation rate of the flow
field in this area. The separation and secondary flow can be observed by blade tip leakage. Moreover, strong flow distortion
resulting from switching the rotating reference frame to station reference frame, along with massive turbulent intensity that
consequence in high local eddy viscosity. The beta angle was alleviated on jet-wake shear layer at the exit area of the compressor.
Consequence in less entropy generation in such area.

Keywords: Entropy, flow passage, centrifugal compressor

1. Introduction integrate in co-generation or tri-generation with

Small gas turbines engines become more practical interesting profitability potential in Thailand. Therefore a
means of power generation. Regarding to several lot of available Micro-turbine manufacturer selecting
advantages comparing to piston engines. For examples, recuperative cycle for their designed process. Most of
capability to operate with various fuel type, including low them provide the thermal efficiency around 30% with
callorific fuel because of the continuous combustion optimum pressure ratio around 4. The compressor is
process, more combustion efficiency, less emission. possible to employ single stage centrifugal compressor at
Although small gas turbine engine compression ratio was this low pressure ratio condition. Moreover, small gas
limited by turbine inlet temperature and components turbine integrated with synthesis gas from gasifier
efficiency. Nowadays, compressor efficiency and turbine (BIG/GT) reactor is currently becoming the most
inlet temperature are increasing with the help of CFD and interesting research topic. Due to their advantage
material technology. Consequence in higher compression comparing with reciprocating engine. Micro-turbine is
ratio and thermal efficiency of small gas turbine engine. capable to consume hot synthesis gas from gasifier reactor
Moreover, gas turbine exhaust gas temperature was at around 500 C, at this temperature tar is in vapor stage
typically much higher than piston engine. Consequence in and then could directly burn in turbine combustor. In
higher potential to recover waste heat from exhaust gas. contrast to reciprocating engine which synthesis gas need
to cool down to room temperature and all tar need to
Thermal efficiency of small gas turbine is strongly remove before deliver syn-gas to engine. Therefore,
depend on its efficiency of 3 components which Micro-turbine is consider to deliver higher system thermal
comprising of 1.) compressor 2.) Combustion chamber 3.) efficiency with gasification reactor integration.
Turbine. In order to achieve high system thermal
efficiency, each components must operate with high
efficiency at their operating condition. The operating
condition of Individual component was obtained from
thermodynamics analysis [16] which aiming to analyst for
the system operating thermodynamics state to achieve the
highest system thermal efficiency with the restriction of
components efficiency and turbine material that able to
withstand the firing temperature. It shows that small gas
turbine engine, with compressor efficiency of 78%
(including combustor pressure drop ) , turbine firing
temperature at 1200K can achieve thermal efficiency
around 30%, which comparable to piston engine. The
recruporative cycle for micro-gas turbine is considered as Fig 1. Thermal efficiency of small gas turbine
high potential for commercial application. It is able to

Vol._ No._ TSME | Journal of Research and Applications

in Mechanical Engineering
 JRAME Numerical simulation of Thermo-Fluid dynamic entropy generation in centrifugal compressors for Micro-turbine application

The Entropy generation is the parameter that

     t  k 
quantitatively indicates on the energy transformation from k   kui         Pk   
useful pressure and kinetics form, to useless thermal t xi x j   k  x j 
energy that dissipated in fluid itself, or so called internal
irreversibility. In compressor, the more dissipation means (3)
   t   
2
more input energy required to obtain the target exit    
pressure and flow rate of the compressor. The local       ui         C1 Gk  C 2
t xi x j     x j  k k
entropy generation is depends on local internal flow field
structure. The entropy generation in compressor and (4)
turbine are largely impact on system thermal efficiency When  k
and   are the turbulent number which
[1]. The entropy generation is generally cast by isentropic
efficiency. In order to design compressor that capable to assigned to be constant equal to 1.0 and 1.3 respectively,
operate with high isentropic efficiency at design p k is the local turbulent generation rate which is
condition. Designer must understand physical flow field proportional to local mean flow velocity gradient, can be
that occur in the flow passage. The flow field computed by the equation below
characteristic is resulting from various interaction.
  u u j  2 ul   u j
Despite two third of the entropy was generated in
Pk    t      k  3  t   ij 
i

diffuser [2] but it has been studied that diffuser efficiency 
was largely dependent on impeller exit flow condition and    x j  x i  3 xl    x i
the interaction at the transition area from impeller to (5)
diffuser inlet was significantly contribute to the overall a Turbulent viscosity (  t ) can be calculated using k–
compressor performance [3]. Flow in diffuser is beyond
the scope of discussion in this paper.  turbulent modeling assumption as below which
depends on local value of TKE and TKE dissipation rate
2
k
t  C
 (6)
When constant parameter C  1 , C  2 and C  are assigned
to be 1.44, 1.92 and 0.09 respectively.

3. Boundary conditions and numerical methodology

Preliminary compressor geometry was obtained
corresponding to the designed thermodynamics cycle for
Fig 2. Compressor Energy analysis 200 kW rated power gas turbines application [16]. The
preliminary design procedure conducted on theoretical
One of the concern in changing any geometry analysis basis that flow detail was not considered and
parameter in order to improve efficiency of the centrifugal many simplified assumptions were applied [4,5]. After
compressor is that the changing may shift the original that, CFD analysis was implement for flow analysis’s
operating condition. It has been investigated work that detail and fine tuning of the flow passage were made in
changing exit beta angle will contribute a little effect on order to achieve high isentropic efficiency and desired
Operating condition shifting [17]. operating condition.

2. Governing equations Table 1. Thermodynamics analysis data

3-D Reynolds averaged compressible Navier–Stokes Isentropic Efficiency of Compressor 85%
equations was used for governing equations. The transport Pressure Ratio 4
of momentum, mass, energy are taken into account. Eddy mass flow rate (kg/s) 1.33
viscosity was computed by k–𝜀 turbulent modeling. Mass
and momentum transport equation can be written as below Table 2. Geometry dimension from [9-11]
 Dimension Size
   ui   0 Inlet impeller diameter (mm) 90
 xi Outlet impeller diameter (mm) 440
(1)
Inlet impeller height (mm) 15
 P    u u j 2 ul  Outlet impeller height (mm) 10
   u iu        ij 
i

x j
j
 xi x j   x  xi 3  xl   Number of impeller / splitter blade 9/9
  j  Impeller speed (rpm) 20,000
   u u j  2  ul   Tip clearance (mm)[8] 1
      k  t  ij 
i
 
x j  x  xi  3  xl 
     3.1 Numerical methodology
+
j
(2)
The computational study has been conducted by
The local entropy generation is depends on mean commercial Ansys CFX Code [15] which was
flow velocity gradient and level of turbulent intensity reputationed in turbo machinery flow modeling. The flow
which can be computed via the equation below. has been modeled with RANS scheme. k–  Turbulent
TKE transport and TKE dissipation transport can be model was employed to predict turbulent property
computed using the transport equation as below transport. Governing equation was discretized by Finite

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 Journal of Research and Applications
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volume method. Flow domain was divided into 630,000

cells of structured hexahedral cell [6,8,14]. Grid
independent was tested by compressor model of previous
research [6,7] .The more grid density was executed in near
wall region to capture more flow property gradient in that
area. The normalized residual convergence criteria of
every transport equation was set at 1.0e-04 [6][4][14].
Model validation was perform and good agreement
outcome was achieved [6]. However, It need to be realized
from the previous research in this area [13]. The different
between steady and unsteady simulation was found.
It showed that the unsteady simulation gave more
accurate result than the steady one. And it has revealed
that the steady simulation (RANS) tends to predicted less
entropy generation than the experiment and unsteady
(URANS) simulation [12-14]. However, this has to be Fig 5. Meridional plane of the computational
trade off with computer resource and more modeling domain
complexity need to be concern. Model validation has been done by comparing the
simulation result from Rigi Test Rig at Turbomachinery
3.2 Boundary Conditions and validations Laboratory.ETH Zurich
- Inlet boundary condition, Static frame total [6,7] where the impeller model A8C41(Albert Kammerer)
pressure was assigned to 1 atm was employed. Good agreement between testing result
- Outlet boundary condition, Average Static Pressure and simulation result was obtained.
was assigned to 4 atm
- Stationary Wall and No-Slip Condition was
4. Results and Discussion
assigned to wall
4.1 Quantitative entropy generation
- Inlet temperature was 30 °C
The flow was modeled in steady flow regime. Air
property was treated as compressible flow.

Fig 3. Compressor geometry

Fig 6. Static entropy at different stream-wise location for
all exit beta angle

Regarding to the Figure 5. The simulation result

shows the same character of entropy generation for all
Beta(𝛽2 ) angle, at the stream-wise location range 0-0.6,
the entropy generation was nearly linear characteristic,
around 60 J/kg.K. But at the area just before the impeller
exit, stream-wise location range 0.6-1.0 the entropy
generation was around 8 times more than the impeller inlet
region which around 480 J/Kg.K. Moreover, the highest
entropy generation was found at the impeller exit region,
in the case exit beta angle of 10 degrees and the lowest
entropy generation was found in the case exit beta angle
of 50 degrees.

Fig 4. Structure hexahedral mesh

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 JRAME Numerical simulation of Thermo-Fluid dynamic entropy generation in centrifugal compressors for Micro-turbine application

4.2 The influence of exit beta angle on secondary flow

region

Fig 9. Entropy distribution of case 10 degree exit beta

angle

Fig 7. Mach number at various stream wise location for

all exit beta angle

Fig 10. Entropy distribution of case 50 degree exit beta

angle
Fig. 9 and 10, shows entropy generation along stream-
Fig 8. Secondary flow at stream-wise location of 0.25 wise location of the impeller blade. It shows that at the
location range of 0.1-0.6 entropy generation was very low,
resulting from non-deformation flow field at the inlet area
At stream-wise location range of 0-0.6, flow stream as stated before. At the location range of 0.1-0.6, the major
line was paralleled with the flow passage (Fig. 11 and 12) source of entropy generation was came from near-wall
because the in-flow angle was same as the angle of the region which shear layer comes from both secondary flow
inlet impeller passage and the flow channel cross area was from blade leakage (Fig. 9 and 10) and boundary layer
throated causing the fluid to accelerate along the flow structure. At the location range of 0.5-0.7, found more
passage in this range (Fig 7). It is easy to manage the flow entropy generation in near-wall region which coincide
in throat region since the flow momentum is become with the observed development on boundary layer and
higher along the passage, so flow separation is more blade tip leakage interaction. However, entropy
difficult to occur in throat region. However, this trade off generation was in the same level as the location 0-0.4
with the flow blockage in throat region which limit allow because the flow in this location was diffused, resulting in
mass flow rate of the compressor. Despite, there are no around 400% lower velocity magnitude (Fig 7). At the
separation could be observed in the impeller inlet area, the location of 0.7-1.0, entropy generation was 3-4 times of
secondary flow was formed from blade tip leakage flow the location 0-0.6 because of the interaction of many
that interaction with flow in the passage (Fig 6.) physical interaction that leading to high deformation flow
In contrast with the Impeller inlet area (0.1-0.6 stream field. Starting from the separation flow in the region
wise), the outlet area (0.6-1.0 stream wise) was difficulted around 0.6 stream wise (Fig. 11 and 12) which was the
to manipulate the flow since the flow was decelerated commence of the two region or jet-wake flow structure,
rapidly due to the wider area passage so called “diffuse”. combine with the observed accumulated secondary flow
Various physical interaction was effected on flow along blade tip and accumulated turbulence intensity that
character in this area. In generally, Jet-wake region was generate from local high shear flow structure and
found (Fig. 13 and 14). The low pressure and low velocity convection from upstream flow.
zone in the back side of the impeller blade was the cause
of the flow separation since this region tend to suck the
flow to separate from jet region. At the impeller outlet, jet-
wake flow structure was interacted with the non-rotation
frame resulting in recirculation flow at the impeller outlet
(Fig 13 and 14). Stronger secondary flow from blade tip
leakage interaction, comparing to the inlet region could be
observed.

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 Journal of Research and Applications
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Fig. 11 velocity structure of 10 degree exit beta angle Fig. 14 Jet-wake and recirculation structure of 50 degree
exit beta angle

Fig. 12 velocity structure of 50 degree exit beta angle

Fig. 15 pressure distribution of 10 degree exit beta angle

Fig. 13 Jet-wake and recirculation structure of 10 degree

exit beta angle
Fig. 16 pressure distribution of 50 degree exit beta angle

The beta angle was influenced on flow structure. The

beta angle or back-swept angle was alleviated on the Jet-
wake shear layer structure. Accelerate flow in wake region
because Beta angle will resulting in smaller flow cross
area (Fig 17) in wake region which cause the flow
acceleration compare to smaller beta angle. In the other
hand, Beta angle also influence in flow deceleration in jet
region because of the wider area in the jet region Fig. 17

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 JRAME Numerical simulation of Thermo-Fluid dynamic entropy generation in centrifugal compressors for Micro-turbine application

[6] Armin, Z., Albert, K. and Abhari, R.S. (2010). Unsteady

Computational Fluid Dynamics Investigation on Inlet Distortion
in a Centrifugal Compressor. Journal of Turbomachinery. 132.
[7] Schleer, M. and Abhari, R.S. (2008). Clearance Effects on the
Evolution of the Flow in the Vaneless Diffuser of a Centrifugal
Compressor at Part Load Condition. Journal of Turbomachinery.
130
[8] Tang, J., Turunen-Saaresti, T. and Lorjola, J. (2008). Use of
partially shround impeller in asmall centrifugal compressor.
Journal of Thermal Science. 17: 21-27.
[9] Baskharone, E.A. (2006). Principle of Turbomachinery in Air-
Breathing Engines, Cambridge University, New York,
Cambridge University Press
[10] Dixon, S.L. (2005). Fluid mechanics and thermodynanics of
turbomachinery, Liverpool, Butterworth-Heinemann.
[11] Florin, L., Trevino, J. and Sommer, S. (2007). Numerical
Analysis of Blade Geometry Generation Techniques for
Centrifugal Compressors. International Journal of Rotating
Machinery
Fig. 17 effect of beta angle that cause smaller area in wake [12] Trébinjac, I., Kulisa, P., Bulot, N. and Rochuon, N. (2009).
region and wider area in jet region Effect of Unsteadiness on the Performance of a Transonic
Centrifugal Compressor Stage. Journal of Turbomachinery. 131.
[13] Dickmann, H.P., Wimmel, T.S., Szwedowicz, J., Filsinger,
5. Conclusion D., and Roduner, C.H. (2006). Unsteady Flow in a Turbocharger
A computational investigation has been undertaken to Centrifugal Compressor : Three-Dimensional Computational
Fluid Dynamics Simulation and Numerical and Experimental
investigate on the characteristic of entropy generation
Analysis of Impeller Blade Vibration. Journal of
along blade passage of the centrifugal compressor, the Turbomachinery. 128:455-465.
effects of impeller exit beta angle on the entropy [14] Pierandreiand, G. and Sciubba, E. (2010). Numerical
generation characteristic is also depict. Four different exit Simulation and Entropy Generation Maps of an Ultra-Micro-
beta angle values are varied for this study. The following Turbogas Compressor Rotor. ECOS 2010, 14-17 June 2010,
conclusions are derived from the computational analysis. Lausanne CH.
All four different exit beta angle are given the same [15] ANSYS CFX-Solver Theory Guide. ANSYS CFX Release
entropy generation characteristic. At stream-wise location 12.1, ANSYS Europe Ltd., 1996-2006.
of 0.1-0.6 the entropy generation is almost the same for all [16] กิ ต ติ ภ าส วศิ น ารมณ์ และจารุ วัต ร เจริ ญสุ ข (2553). การออกแบบและวิเ คราะห์
four cases which is very little comparing to impeller exit สมรรถนะห้องเผาไหม้เครื่ องยนต์ก ังหัน ก๊าซขนาดเล็ก ( 200 กิ โลวัตต์), การประชุ มวิชาการ
region. At the impeller exit region (0.6-1.0 stream-wise) เครื อข่ ายวิศวกรรมเครื่ องกลแห่ ง ประเทศไทยครั้ งที่ 24, 20-22 ตุ ลาคม 2553 จังหวัด
massive entropy generation occur. Because there are อุบลราชธานี .
several physical interaction in this area. [17] เดชดนัย บุญช่วย. 2554. “การจาลองเชิงตัวเลขคอมเพรสเซอร์ แบบแรงเหวี่ยงสาหรับ
The exit beta angle is effects on the impeller outlet เครื่ องยนต์ก ัง หัน ก๊ าซขนาดเล็ก (200 กิ โ ลวัต ต์) .” วิท ยานิ พนธ์ปริ ญญาวิศ วกรรมศาสตร
flow pattern. Resulting in less entropy generated. The มหาบัณฑิต สาขาวิชาวิศวกรรมเครื่ องกล บัณฑิตวิทยาลัย, สถาบันเทคโนโลยีพระจอมเกล้าเจ้าคุณ
lowest entropy generation is observed in the case of beta ทหารลาดกระบัง.
angle 50 degree. The highest entropy generation occur in
the case of beta angle 10 degree. The flow field velocity
shows that exit beta angle effect on the flow structure in
exit area, alleviate on the jet-wake shear layer and also
impeller exit flow distortion, with its changing in exit flow
angle.
The separation flow was earlier found in the case of
low Beta angle. Also higher deformation rate of flow
structure can be observed in the case of low beta angle.

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[3] Liu, R. and Xu, Z. (2004) Numerical investigation of a high-
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[5] Asuaje, M., Bakir, F., Smaine, K., and Rey, R. (2004). Inverse
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