Case Study: ARCA Valves achieves 25% higher flow coefficient (Kvs) with CAESES

CFD-Driven Shape Optimization of a Control Valve

ARCA Valves needed a high-flow DN700 control valve optimized for use as an anti-surge valve on turbocompressors, able to handle liquid and gaseous media and meet strict constraints (wall thicknesses, flanges, seat/cage positions). The main challenge was creating a flexible, parameterized housing geometry that respected these constraints; the parametric model was built in CAESES and the CFD evaluations were performed with Autodesk CFD.

Using CAESES, a CFD-driven shape-optimization workflow was implemented: inlet/outlet channels were controlled by parameterized contours and an elliptical swept cross-section, with fixed flange, plug seat ring and cage geometry and a movable seat. The CAESES-led optimization increased the flow coefficient Kvs by ~25% versus the baseline (exceeding the target by ~3%), cut development time (about two weeks to set up and run the optimization), enabled exploration of unconventional concepts, and greatly reduced the need for physical testing.

ARCA Valves