CFturbo in use at University of Bath – Turbomachinery Research Centre (bath.ac.uk)
The Turbo-Machinery Research Centre at Bath University investigates the theoretical, computational and experimental modelling of heat transfer and fluid flow related to Turbo-Machinery. One recent project that formed part of a Masters Engineering student’s final degree was that relating to the Design of a Turbopump Compressor used within space launch vehicles.
Liquid rocket propulsion is an integral part of the modern space industry. Notable launch vehicles such as the SpaceX Falcon 9, CNSA Long March 8, ESA Ariane 5, and ULA Atlas V all utilise liquid rocket engine systems, alone or in combination with solid boosters to conduct a variety of missions – from ISS transportation to satellite delivery. This is because of their notable efficiency, versatility and, more recently, reusability.
Alfie Gilmour’s Final Year Dissertation was entitled ‘Design and Optimization of a Hydrogen Peroxide Turbopump Compressor’ and made use of CFturbo extensively. The following Case Study provides a summary of the work undertaken; however, the full report can be requested if you contact us at info@8020engineering.com
Research – Case Study Work

In light of more sustainable propulsion, environmentally-clean rocket propellants are a key driver in assuring the future of space travel, especially for the feasibility of commercial orbital launches and beyond. Rocket grade hydrogen peroxide (HTP) was typically reserved for limited performance applications due to pressure-fed propellants or low-performance turbopump cycles. However, in the last decade, interest has been rekindled into its use in the next generation of liquid rocket engines due to its low toxicity, clean combustion products, and attainable Specific Impulse. Thus, the presented work aims to initiate the development of a high pressure, lightweight and compact turbopump system for use with HTP and RP-1 fuel. The ultimate goal is to achieve an efficient configuration that promotes the benefits of adopting the propellant.
One of the objectives of the thesis project was to use CAD modelling software to generate geometry which was then compatible for analysis with the chosen CFD and FEA software packages.
The core focus was the development of the inducer, impeller, and volute geometries. An iterative inverse design approach was adopted to ensure each configuration was optimized for performance, with respect to a specification outlined by silver-screen catalyst bed requirements.
1D modelling tools were constructed which outputted blade angles and characteristic parameters to define initial component design points. A commercially available turbomachinery modelling software, CFturbo, was then used to generate practical 3D geometry (figure 2). CFD simulations (figure 3) then predicted internal flow performance, quantified by total pressure rise and efficiency, and also validated the 1D model outputs.



Following three iterations, the baseline compressor produced a total pressure rise of 512 ??? and an efficiency of 81.1%, at a shaft speed of 90,000 ??? and a mass flow rate of 8.00 ??/?. Despite this not complying with the 360 ??? pressure rise requirement, it was proposed to run the pump at a low power mode to decrease the outlet pressure to acceptable levels.
FEA studies were conducted in parallel to feedback to the design loop on load bearing and dynamic performance. Baseline results predicted total material failure but highlighted several areas for design improvement. Modal analysis results showed no natural frequencies coincided with the pump operating window.
A subsequent optimization study was conducted to investigate the effects of splitter blades on pump performance. A clear relationship between the splitter blade leading-edge meridional position and pump efficiency was identified. This defined an optimum impeller configuration, which gave an efficiency increase of 1.6% at a splitter blade leading-edge position of 30% meridional length. A significant reduction in streamline deviation was observed within the impeller blade channels as a result. Revised inducer and impeller models fell within permissible stress and displacement limits, with a 4.8% improvement to inducer mass, although the impeller suffered an increase of 8.4% due to the addition of the splitter blades and thicker hub/shroud geometries.
Ultimately, a high pressure, high efficiency, lightweight and compact prototype was devised. All critical design requirements were proven to be attainable with a slight adjustment to the operating conditions. The implementation of splitter blades, not previously covered for HTP turbopump systems by modern literature, was successfully explored.

80/20 Engineering is a specialist Fluid Flow/Thermal Simulation Software and Consultancy Company. We have a long track record of helping companies implement ‘Design Friendly’ or ‘UpFront CFD’ user environments that we believe will play an ever-increasing role within the product development process. However, often the client project demands are such that there is an urgent need for a design to be improved or a problem resolved. In these situations, we also have a team of experienced simulation engineers to call upon.