CFD based Performance Prediction of Centrifugal Compressor

In modern engineering, compressors play a vital role across numerous industries by enabling the delivery of fluids at elevated pressures for a variety of applications, including HVAC systems, aircraft engines, and process industries. The performance of centrifugal compressors, in particular, is characterized by parameters such as flowrate, efficiency, and pressure rise, all of which are critical to the reliability and efficiency of associated equipment. Traditional methods of evaluating compressor performance, such as physical testing, are often time-consuming and costly, making them less practical for iterative design or optimization. Advancements in Computational Fluid Dynamics (CFD) have provided a faster and more cost-effective means of assessing compressor behavior. This study presents a comprehensive CFD-based analysis of a two-stage centrifugal compressor utilized in HVAC applications, with a focus on predicting surge points and mapping the surge line at various operating speeds. Simulations were conducted using the ANSYS CFX software, enabling detailed investigation of individual component contributions and supporting rapid design optimization efforts. The results illustrate the effectiveness of CFD in accurately predicting critical performance metrics and operational limits for centrifugal compressors. Additionally, the study explores the impact of different geometric modifications on compressor stability and surge margin, providing valuable insights for future design improvements. Furthermore, the model’s accuracy was validated against available experimental data, demonstrating reasonably good agreement and reinforcing the practical applicability of the proposed methodology. The findings emphasize the pivotal role CFD tools play not only in reducing development time and costs but also in enhancing the overall design process by enabling engineers to identify and address potential issues in the early stages. This work highlights the importance of integrated simulation approaches in achieving higher efficiency and reliability in compressor technology, that can be adapted to compressors used in aerospace engines.