Technologies

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Ebara Engineering Review No.237

Advancement and Future of Turbomachinery Flow Optimization Technology

by Akira GOTO

Further advancement of fluid engineering technology for turbomachinery requires breakthroughs in both “simulation technology” and “design technology”. Thanks to remarkable developments in computational science and high performance computing, “simulation technology”, including fluid simulation, has evolved steadily and dramatically. While the limitations of 2D based “design technology”, including the use of empirical design diagrams, have become evident, a 3D inverse design method using fluid dynamic design parameters has been proposed and successfully applied to multi-objective and multi-disciplinary numerical optimization. Innovations in fluid engineering technology will hopefully continue with strong academia-industry collaboration and rapid progress in information and communication technologies.

Keywords
Turbomachinery, Numerical optimization, High performance computing, Computational fluid dynamics, 3-D design, Inverse design method, Multi-objective optimization, Multi-disciplinary optimization, Explicit knowledge, Academia-industry collaboration

The Development of Sheet Metal High Efficiency Impeller

by Junya KAWABATA, Akira GOTO, Takashi ENOMOTO, & Kosuke ASHIHARA

Many stainless steel sheet metal impellers are used in relatively small pumps since they provide excellent volume efficiency. On the other hand, the shape of these impellers is virtually identical to that of conventional cast impellers since the shape of general cast impellers provides an approximate template for the shape of press-formed sheet metal impellers.
To improve the performance and efficiency of stainless steel sheet metal impellers, we have developed an impeller in the innovative shape of an S-shaped meridian, by designing it in the shape of a blade surface through an inverse design method and then narrowing down various parameters by numerical analysis. The performance of the impeller, which was developed to achieve a relative velocity of 120 to 280 (min-1, m3/min, m), was tested in the same casing in which conventional impellers are used, the tests verified that it achieved a pump efficiency improvement of about 0.5% to 14% over conventional impellers.

Keywords
CFD, Inverse design method, Stainless steel sheet metal impeller, Meridian shape

Current Market Situation for and Future Technology Trends in Solid Waste Treatment

by Ryuichi ISHIKAWA

In Japan, solid waste treatment through incineration was mandated in the Meiji period to improve public sanitation. Since 1963, the enactment of legislation and the provision of government subsidies accelerated the introduction of mechanical furnaces. Exhaust gas treatment technology has also been advanced to address environmental issues, such as pollution problems and dioxins. High-efficiency power generation technology and incineration residue melting technology have been developed for the purpose of contributing to a low-carbon and recycling-based society. Thus, fluidized-bed incinerators and gasifiers have been developed and introduced in addition to mechanical incinerators. As outsourcing to the private sector has become increasingly popular, the provision of total technical services for efficient, safe, and stable waste treatment and the effective use of energy are required.

Keywords
Solid waste, Treatment technology, Technology trend, Incinerator, High-efficiency power generation

Innovative Design and Manufacture of Process Gas Centrifugal Compressors

by Yoshiro FUKASAKU, Shin KONOMI, & Naoyuki HASEGAWA

The Elliott Group supplies process gas centrifugal compressors to meet diverse market needs in industries ranging from oil refining, to petrochemical production, to the oil & gas industry and even to the production of liquefied natural gas. To meet the growing customer demand for improved compressor performance and reliability and to shorten delivery process, the company has developed and marketed new compressor models since the late 1990s. The Elliott Group seeks to systematically integrate already developed and established components into these new models. However, newly developed compressor components, which address current market needs, have also been introduced. Innovative manufacturing techniques, based mainly on machining, rather than on casting and welding, have been actively pursued.

Keywords
Centrifugal compressors, New compressor models, High speed, Plant capacity increase, Manufacturing technologies, Machining, Market expansion, Petrochemical industry

New CMP System, Model F-REX300X

by Junji KUNISAWA

CMP systems are used for the planarization of the layers in forming the multi-layered interconnects of a semiconductor device. For the improvement of device performance, miniaturization of semiconductor devices has been promoted continually. The materials and processes used in the manufacture of semiconductor devices have become increasingly diversified in the pursuit of cutting-edge technology; consequently, the need for flexible semiconductor manufacturing systems has become even stronger in order to accommodate various processing conditions. Our new CMP system, Model F-REX300X, is equipped with new transport and cleaning mechanisms in combination with the technology that has been cultivated over many years through our CMP projects. This system has both excellent flexibility and high productivity in polishing processes, which enable it to readily accommodate the strict requirements of the most advanced processes.

Keywords
Throughput, Equipment Front End Module, Front Opening Unified Pod, FOUP load port, Overhead, Footprint, Particle, Two-fluid jet, Modularization, Marangoni

Increase in Pump Performance Using the Existing Structural Design
(Reconstruction of the Pump Facility at the Sanryo Drainage Pump Station)

by Hiroyuki OSAWA, Sakae SHIMIZU, Koichi TACHIBANA, & Toshiyuki KUTSUWADA

This paper reports the reconstruction of the Sanryo Drainage Pump Station first constructed over 40 years ago.
Regardless of constraints, such as the reuse of the existing casing, increased pump capacity, and change of the impeller type, pump efficiency was increased by about 5%.
A new technique was used to level the pump base on-site. Through the reuse of the existing casing, the renewal of the vertical volute type pump with concrete casing was successfully completed, a job that was previously considered impossible to complete within six months of dry season.
These results provide a guideline for the future reconstruction of large-scale drainage pump stations.

Keywords
Concrete casing, Reconstruction, Increase in pump performance, Vertical volute type mixed flow pump, Reuse, Underground structure, Drainage pump station, Dry season, Impeller, Pump efficiency

Vertical Pump with Total Length of 88 m - Water Intake Pump Used in Las Vegas -

by Tomohiro YOSHIDA, & Dai KUDO

Designing the vertical mixed flow pump delivered in 2009 to Las Vegas, United States, presented many technical challenges because its total length of 88 m was the longest in the history of our large pump deliveries. Based on examination informed by our broad experience in the manufacture of vertical pumps and through verification by analysis, we solved such technical challenges as the accumulation of production errors, the difficulty with dimensional tolerance control due to shaft stretch in the longitudinal direction, the dry running of submerged bearings at start-up, and vibration problems. The long pump has been designed to allow simple and efficient installation; it also has reduced weight so as not to exceed the crane capacity. The pump has already been installed on-site and is in commercial operation.

Keywords
Vertical pump, Intake pump, Pump total length, Dimensional tolerance control, Weight reduction, Dry running, Finite element method, Lateral vibration, Torsional vibration