Numerical Study on a High-Pressure Stage in Synthesis Gas Compressor

Abstract

Numerical study on the first stage of the high-pressure casing in an industrial synthesis gas (syngas) compressor is presented here. Detailed flow field comparisons are made between impeller/stage models. The stage model is composed of impeller, vaneless diffuser, bend and return channel, while the impeller model is composed only with impeller and vaneless diffuser. Compared to the results from stage model, the impeller model results indicate that the predicted aerodynamic performance is higher, and operating range is wider in both stall and choke side. Under the same inlet volume flow rate, the blade pressure coefficients, Mach number and flow angle in the blade passage for both models are nearly the same, suggesting that the flow field data in the rotating impeller is to some degree credible for stage performance prediction. However, as the impeller model neglects the matching effect with the downstream stationary parts, there needs some correction for stage working range with stable operation. Besides, the internal flow fields of stage using air and syngas mediums are compared respectively. Results indicate that the aerodynamic performance and operation range are different for both mediums because of different density and gas constant. For the flow field of the whole stage, large discrepancy occurs in the leading edge of the return channel under the same inlet volume flow rate. It suggests that the existing air model stage couldn't be directly used for the syngas compressor and needs redesigning.