CFD Simulation of Fluid Machinery

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Chemical Processes and Systems".

Deadline for manuscript submissions: 31 May 2026 | Viewed by 1489

Special Issue Editors


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Guest Editor
Laboratory of Fluid Dynamics and Particulate, Federal University of Pará, Tucuruí 68455-901, PA, Brazil
Interests: fluid mechanics; water resources management; computational fluid dynamics; renewable energy

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Guest Editor Assistant
Faculty of Mechanical Engineering, Federal University of Triângulo Mineiro, Uberaba 38064-200, MG, Brazil
Interests: mechanics; cavitaiton; CFD; turbomachinery; energy and fuels

Special Issue Information

Dear Colleagues,

Multiphase flow in turbomachinery represents a challenge for CFD modeling, particularly when simultaneous phenomena such as cavitation and sediment erosion are involved. In hydraulic turbines, although cavitation is a widely studied issue, important gaps remain, such as the accurate identification of cavitation zones. Classical correlations do not provide reliable predictions of these limits, especially in the transition between Francis and Kaplan turbines. The complexity increases further in sediment-laden scenarios, where solid particles interact with cavitation. In such cases, solid–fluid–vapor multiphase models become indispensable for identifying erosion zones. We encourage contributions that propose new cavitation formulations to improve CFD predictions, as well as the use of data-driven or CFD-AI approaches capable of enhancing predictive capabilities in complex scenarios. Contributions exploring the application of existing models under challenging conditions are also welcome. The CFD models should be supported by experimental validation to ensure reliability. Although motivated by hydraulic turbines, the scope extends to flow machines in general, involving cavitation and/or sediment erosion, opening opportunities for methodological advances that benefit a wide range of applications. We therefore invite the scientific community to contribute studies that advance the use of CFD in addressing these challenges.

Prof. Dr. André Luiz Amarante Mesquita
Guest Editor

Dr. José Gustavo Coelho
Guest Editor Assistant

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Keywords

  • turbomachinery
  • multiphase flow
  • CFD modeling
  • hydropower
  • cavitation
  • slurry pump
  • hydraulic turbines
  • hydraulic machinery

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Published Papers (4 papers)

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Research

26 pages, 14423 KB  
Article
A Study of Abrasive Solid Particles Erosion for a Centrifugal Pump Operated as a Pump and as a Turbine Using Computational Fluid Dynamics
by Jamal El Mansour, Patrick Hendrick, Abdelowahed Hajjaji and Fouad Belhora
Processes 2026, 14(4), 707; https://doi.org/10.3390/pr14040707 - 20 Feb 2026
Viewed by 226
Abstract
Impeller blades are one of the main parts of a centrifugal pump that affect the performance of the pump. The presence of solid particles in seawater, transported through a centrifugal pump, causes wear in the blade surface that reduces blade lifetime. In the [...] Read more.
Impeller blades are one of the main parts of a centrifugal pump that affect the performance of the pump. The presence of solid particles in seawater, transported through a centrifugal pump, causes wear in the blade surface that reduces blade lifetime. In the orthogonal direction, this wear is an erosion thickness of the blade. Assuming that these particles have a spherical shape, the erosion rate depends on their velocity, size, impingement angle, and material hardness index. In this work, we investigate the erosion thickness of a low-head centrifugal pump operating in pump and turbine modes, with a particle radius ranging from 4 μm to 50 μm. The numerical simulation used an RNG k–ε turbulence model, assuming a perfect bounce collision between the particle and the rotating solid wall. The study shows that the blade pressure side is impacted by a solid particle concentration higher than the suction side. In pump mode, the erosion thickness on the blade sides increases if the particle radius is above 4 μm and reaches a maximum at 40 μm. In turbine mode, the erosion thickness decreases when the particle radius is greater than 5 μm. The thickness loss is greater in turbine mode than in pump mode. The influence of particle flow rate was investigated. Below a particle radius of 10 μm, particles follow the flow directions and reside for a longer time in the blade channel. Passing from a particle radius of 50 μm to 100 μm, the blade lifetime was decreased by a factor of 11. Full article
(This article belongs to the Special Issue CFD Simulation of Fluid Machinery)
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23 pages, 4797 KB  
Article
Rotor–Stator Interaction-Induced Pressure Pulsation Propagation and Dynamic Stress Response in an Ultra-High-Head Pump-Turbine
by Feng Jin, Le Gao, Dawei Zheng, Xingxing Huang, Zebin Lai, Meng Liu, Zhengwei Wang and Jian Liu
Processes 2026, 14(2), 311; https://doi.org/10.3390/pr14020311 - 15 Jan 2026
Viewed by 293
Abstract
Unsteady flow-induced pressure fluctuations and the consequent dynamic stresses in pump-turbines are critical determinants of their operational reliability and fatigue resistance. This investigation systematically examines the spatiotemporal propagation of Rotor–Stator Interaction (RSI)-induced pressure pulsations and evaluates the corresponding dynamic stress mechanisms based on [...] Read more.
Unsteady flow-induced pressure fluctuations and the consequent dynamic stresses in pump-turbines are critical determinants of their operational reliability and fatigue resistance. This investigation systematically examines the spatiotemporal propagation of Rotor–Stator Interaction (RSI)-induced pressure pulsations and evaluates the corresponding dynamic stress mechanisms based on a phase-resolved fluid–structure interaction strategy. The results reveal a significant hydrodynamic duality: RSI pressure waves manifest as convective traveling waves on the pressure side but as modal standing waves on the suction side. Crucially, a severe spanwise phase mismatch is identified between the hub and shroud streamlines, which induces a periodic hydrodynamic torsional moment on the blade. Due to the rigid constraint at the blade–crown junction, this torsional tendency is restricted, resulting in high-amplitude constrained tensile stresses at the root. This explains why the stress concentration at the crown inlet is significantly higher than in other regions. Additionally, the stress spectrum shows strong load dependence, characterized by low-frequency modulations on the suction side under high-load conditions. Full article
(This article belongs to the Special Issue CFD Simulation of Fluid Machinery)
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18 pages, 4725 KB  
Article
Structural Parametric Study of an Ultra-High-Head Pump–Turbine Runner for Enhanced Frequency Safety Margin
by Meng Liu, Feng Jin, Xingxing Huang, Dawei Zheng, Zhengwei Wang, Zebin Lai and Jian Liu
Processes 2026, 14(2), 284; https://doi.org/10.3390/pr14020284 - 14 Jan 2026
Viewed by 249
Abstract
Structural optimization focusing on the root fillet radius and the crown and band thicknesses was implemented to prevent rotor–stator interaction-induced resonance, with the objective of enhancing the frequency safety margin for the 4-nodal-diameter mode shape. An ultra-high-head pump–turbine runner is analyzed using an [...] Read more.
Structural optimization focusing on the root fillet radius and the crown and band thicknesses was implemented to prevent rotor–stator interaction-induced resonance, with the objective of enhancing the frequency safety margin for the 4-nodal-diameter mode shape. An ultra-high-head pump–turbine runner is analyzed using an acoustic fluid–structure coupling method to investigate modal characteristics and identify effective design improvements. The results show that increasing the root fillet radius from 0 to 50 mm raises the frequency safety margin from 3.7% to 8.5%, thereby significantly reducing the resonance risk. Likewise, increasing the thickness of the crown, the band, or both leads to higher frequency safety margins, with simultaneous thickening of both components delivering the most improvement. Frequency safety margins continue to rise as the degree of thickening increases. When a runner’s natural frequency is only slightly higher than the corresponding excitation frequency, design measures such as enlarging the root fillet radius and jointly thickening the crown and band effectively expand the frequency safety margin. These findings can provide designers with both qualitative and quantitative references when modifying these structural parameters to mitigate resonance risk. Full article
(This article belongs to the Special Issue CFD Simulation of Fluid Machinery)
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20 pages, 6161 KB  
Article
Comparative Study of Structural Designs of Stationary Components in Ultra-High-Head Pumped Storage Units
by Feng Jin, Guisen Cao, Dawei Zheng, Xingxing Huang, Zebin Lai, Meng Liu, Zhengwei Wang and Jian Liu
Processes 2025, 13(12), 3826; https://doi.org/10.3390/pr13123826 - 26 Nov 2025
Cited by 1 | Viewed by 399
Abstract
Pumped storage power stations provide essential benefits to power grids by cutting peak loads, filling valleys, and boosting renewable energy integration rates. They serve as the foundation for developing a new power system based on renewable energy. Pump turbines are currently evolving to [...] Read more.
Pumped storage power stations provide essential benefits to power grids by cutting peak loads, filling valleys, and boosting renewable energy integration rates. They serve as the foundation for developing a new power system based on renewable energy. Pump turbines are currently evolving to provide higher heads, larger capacities, and higher rotating speeds. The performance and dependability of its basic components have a direct impact on the safety and stability of unit operation. Based on this, this research looks into the modal characteristics and structural aspects of essential stationary components, such as the pump-turbine head cover. By comparing the mechanical performance of two different structural designs (Design A and Design B), Design B features an overall thickness 1.5 times that of Design A and incorporates an upper flange structure. Its design aims to enhance the component’s resistance to bending and deformation, optimize stress distribution while reducing peak stress values, and improve modal characteristics. This approach elevates the overall structural performance of the fixed components to accommodate the complex operating conditions of ultra-high-head pumped storage units. It was discovered that Design B had greater bending and deformation resistance than Design A, as well as better stress distribution and lower maximum stress values. This study further indicates that variations in structural design lead to significant differences in modal characteristics and overall structural performance. In particular, the thicknesses of the head cover’s main body and stiffening ribs are critical parameters that govern the modal behavior and structural properties of stationary components. These insights provide critical technical guidance for optimizing the design of stationary parts, such as the head cover, in pumped storage power plant units. Full article
(This article belongs to the Special Issue CFD Simulation of Fluid Machinery)
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