Impact case study database

Spin Out: PDM Analysis

The creation of SCORG software and its immense potential led to the establishment of PDM Analysis Ltd (PDM), a City, University of London spin-out with the responsibility of commercialising the software.[text removed for publication]. [5.1]. PDM has established global partnerships with leading companies in the field of CAE software, such as Simerics (US), Gamma Technologies (US) and through them distribution agreements with 80/20 Engineering Ltd (UK), Hi-key Technology Corporation Ltd (CH) and Wave Front Co. (JP). Simerics has been using SCORG with one of its two primary products, Simerics-MP+ and has integrated the software with their own CFD tool Pumplinx [5.2]. Clients for the final suite in its various forms include DM8 Composites, HSMarine, Hyundai, Dasault and others.

Likewise, Gamma Technology (GT) has created a seamless integration between SCORG and their leading CAE product GT-SUITE. The partnership offers customers reliable advanced simulation capabilities for screw machines based on the complementary strengths of each tool. [5.3] This partnership has allowed the software to reach clients such Mercedes Benz India, Borg Warner, GM Powertrain and others. GT have confirmed that thanks to this partnership they have seen an increasing number of screw machine OEMs (ranging from air compression to air conditioning) adopt simulations via the combined use of GT-Suite and SCORG [5.3]. Use of simulation leads to reduction in the number of design iterations during product development, reducing physical testing, and shortening the product time to market. The increased efficiency in the design process also helps reduce greenhouse gas emissions by curtailing electric energy consumption (current estimate is that 25% of electricity usage in US during summer months is related to compression) [5.3]

Industry Partners: Howden Compressor Ltd, Scotland, UK

Howden is a world-class engineering company with 6,000 employees in 27 countries and is undergoing a period of significant business growth. It provides high-quality air and gas handling products and services to the power, oil & gas, mining and petrochemical industries, with an estimated annual revenue of $351M. Howden has a long-established partnership with City, University of London, which has been instrumental in fostering a decade of rejuvenated research and development within the company [5.4]. During the current period (2014-20) Howden utilised SCORG in the development of the world’s largest oil injected twin screw compressor with 580mm diameter rotors (2016). Digital prototyping with SCORG provided the high level of confidence required to make the significant investment in a physical prototype. This successfully validated the compressor design. By avoiding the need for extensive design iteration and repeat testing, the prototype could be used in commercial projects [5.4].

Howden also utilised SCORG in 2017, during the key phase of the design of a new range of oil free compressor. This work utilised the fast, efficient chamber model and geometry editing features available in SCORG to study a wide range of designs [5.4]. The project,[text removed for publication], led to the launch of the new range of compressors, which aims at increasing its share on the global oil-free screw compressor market by 2021 [5.5] Howden continues to utilise SCORG in product development and education, and in their R&D department when providing critical business support; this can range anywhere from contract proposals through to contract testing [5.4].Thanks to this long standing collaboration Prof. Kovacevic has been named Howden Chair in Engineering Design and Compressor Technology since 2008 and in 2020 he became the Howden / Royal Academy of Engineering Research Chair in Compressor Technology [5.6]

Global Impact: Kirloskar (India) and Mayekawa (Japan)

The quality of the research and the software has enabled SCORG’s impact to extend beyond UK borders. Two major international companies operating in the compressor industry have utilised SCORG with positive results. Kirloskar Pneumatic Company Limited (KPCL) has collaborated with Prof Kovacevic and his team since 2015 in a two-phase project. Phase 1 (2016-2019) saw the successful development of a new range of oil injected screw compressors, as well as the creation of a team of dedicated engineers within the KPCL [5.7]. KPCL proceeded with the investment of over £500K to phase 2 (2019-2022), with the aim of developing the best-in-class screw compressors and opening new markets. [5.7].

Similarly, Mayekawa Manufacturing approached the university in 2018 based on the strength of the research generated by the Compressor Centre and Prof Kovacevic’s team. . [text removed for publication]. [5.8]

Both companies have utilised SCORG extensively and have experienced significant positive impact in their development processes. KPLC found that on average 1-2 months of the experimental validation for a design change were saved, along with corresponding savings in man-hour rates and flexible modification costs [5.7]. Mayekawa, found that SCORG helped the company to better map, analyse and understand the processes withing the screw compressor and allowed reducing time-consuming experimentation [5.8]. [text removed for publication]. [5.8].

Continued Industry Engagement and Commercialisation

The success of the Centre and SCORG continues to grow, attracting further interest, engagement, and collaboration with industry. The main vehicle for this is the biannual “International Conference on Compressors and their Systems”, organised by City, University of London and the Compressor Centre. Its 11th iteration, held in 2019, attracted more than 250 attendees from 24 countries, led to the publication of 94 technical papers and hosted 10 exhibitors [5.9] The conference is of such importance to the compressor industry that exhibitors such as Vert Rotors UK Ltd use it as a platform to announce new products [5.10]. SCORG itself continues to attract clients from across the globe such as Ingersoll Rand–Trane, Dow Chemical Company, Hitachi Europe GmbH increasing its impact globally [text removed for publication]. [5.11]