Experimental investigations and 3D simulations by the overset grid method on twin-screw machines in both pump and turbine mode

Twin-screw pumps due to their particular capabilities, offer u nique b enefits in comparison to other types of pumps. They can also recover wasted energy from the fluid system when run in a reversed way, i.e., in turbine mode. In this study, the possibility of benefiting twin-screw machines instead of conventional control valves in order to recover energy is investigated. Flow physics and energy recovery are analyzed experimentally and by 3D flow simulations in both, pump and turbine mode. Pump and turbine characteristics under different operating points are experimentally measured for low and high viscous fluids, i.e., water and oil, respectively. It is observed that for higher viscosity the dependency of volume flow rate on the pressure difference imposed on the pump is reduced. This observation indicates the significant effect of viscosity on the gap flow. Based on a simulation method by means of overset grid technique, unsteady 3D flow simulations with a high grid quality and a high spatial resolution particularly in gap regions in terms of y⁺ < 1 are conducted and results are validated against experiments. The profound assessment of gap flow based on the simulation results shows that for highly viscous fluids such a soil, the rotational speed of spindles as well as the direction of rotation have a significant effect on gap flow characteristics and consequently on the pump and turbine performance. From the experiments, it is clarified that with a lower rotational speed of spindles and a higher pressure difference, a higher amount of energy up to about 50% of the fluid energy in the piping system can be recovered instead of being dissipated by a conventional control valve.