A new path in compressor valve design: Optimizing rotary cupped valves for superior flow and efficiency

Abstract

Traditional optimization methods for reciprocating compressor valves are primarily suited for self-acting valves with elastic components, where parameters such as thrust coefficient and Mach number impose mutual constraints, thereby limiting performance improvements. To address limitation, a novel rotary cupped valve has been proposed, achieving precise control through valve core rotation and reducing dependency on gas and spring forces. To meet the design requirements of the full process control type valve, a new mathematical optimization model was developed, and its performance was quantitatively analyzed and optimized through ANSYS fluid-structure coupling numerical simulations. Experimental results demonstrated that, compared to traditional self-acting plate valve, the novel valve reduces leakage by 5 %, increases the flow coefficient by 8.16 %, expands the effective flow area by 88.64 %, and decreases pressure loss by 40.36 %. The model's calculations are in good agreement with experimental results, with a maximum error within 5 %. Additionally, the full opening time of the novel rotary cupped valve is extended by 66.7 % compared to traditional valves, with an increase in capacity by 6 % and a reduction in power consumption by 0.6 %, demonstrating significant engineering application value and promising prospects for further development and widespread adoption.