Loss-Based Optimization of Static Components in Single-Stage Centrifugal Compressors

In single stage centrifugal compressors, each component is pivotal to achieve high performance. However, during the development of new stages, the complexity of impeller often draws the attention, leading focus to its optimization and overlooking an equally detailed study for downstream static components. This imbalance represents an opportunity for compressor manufacturers, especially when market demand shifts toward more efficient and compact machines. Although full stage optimization might be the suitable choice, the associated time and effort often conflict with the typical limitations of the industrial scenario. In light of this, the present study describes the optimization of a single-stage centrifugal compressor, starting from the measurement of the aerodynamic losses on a real test case. Loss analysis and the upgrade of diffuser allowed to increase stage efficiency while limiting radial size and avoiding impeller redesign. In this prospective, the theoretical contribution of the research is to demonstrate the importance of analyzing aerodynamic loss sources for improving efficiency in single-stage centrifugal compressors. On a practical level, the study provides practitioners with a methodological framework to increase stage efficiency without redesigning the impeller. This research lays the foundations for targeted optimization strategies that address performance bottlenecks without requiring a complete redesign of the stage.