On-line oil-free preparation system and method for compressed air with high pressure of 45 MPa

Abstract

The invention relates to an on-line oil-free preparation system and method for compressed air with the high pressure of 45 MPa. The system and the method are long in service life, high in gas production pressure, high in automation degree, capable of being remotely controlled and capable of achieving oil-free compression and comprise a medium-pressure oil-free compression device, and the medium-pressure oil-free compression device is used for compressing free-state air to medium pressure; the drying and purifying device is used for filtering, adsorbing and drying the medium-pressure gas compressed by the medium-pressure oil-free compression device; the buffer device is used for buffering the medium-pressure air filtered and dried by the drying and purifying device; the supercharging device is used for carrying out secondary supercharging on the medium-pressure air in the buffer device; and the control system is used for carrying out power distribution on each device, carrying out process control according to a preset program, and monitoring and displaying operation parameters of each device.

Description

Technical Field

[0001] The present invention relates to a high-pressure air preparation system, in particular to an online oil-free preparation system and method for high-pressure 45MPa compressed air. Background Art

[0002] High-pressure clean air is a common and important gaseous medium required in rocket launch testing. Depending on the requirements of the rocket system, the required air pressure level can generally reach 35MPa or 45MPa. To prevent the test medium from harming the rocket system, high requirements are placed on the high-pressure air's dew point, dust particle diameter, solid particle concentration, and oil content. To meet the high-quality requirements of high-pressure compressed air, there are four traditional high-pressure air production processes:

[0003] 1) High-pressure oil-filled piston compressor compression → filtration → oil removal → drying → finished gas;

[0004] 2) Low-pressure oil-filled screw compressor compression → high-pressure oil-filled piston compressor compression → filtration → oil removal → drying → finished gas;

[0005] 3) High-pressure oil-free piston compressor compression → filtration → drying → finished gas;

[0006] 4) Low-pressure oil-free screw compressor compression → filtration → drying → high-pressure oil-free piston compressor compression → finished gas.

[0007] The primary characteristic of the first two compressed air production processes is the presence of oil in the air, necessitating oil removal prior to external supply. This degreasing process typically utilizes adsorption, which involves the use of absorbent materials (such as activated carbon) to adsorb the oil. However, the adsorption capacity of the adsorbent material is limited, requiring replacement once saturated, and determining when saturation has occurred is difficult. This typically requires testing the finished gas for oil content before downstream delivery, making online air supply inefficient and inconvenient.

[0008] The main features of the latter two compressed air production processes are oil-free compression, no need for oil removal treatment, online air supply, high external air supply efficiency, and simple and convenient use. However, the sealing materials (piston rings and fillers, etc.) used in high-pressure oil-free piston machines need to be replaced regularly. The higher the exhaust pressure, the shorter the replacement cycle. Moreover, due to limitations in sealing technology and maintenance costs, the maximum exhaust pressure of high-pressure oil-free piston machines generally does not exceed 35MPa. When the exhaust pressure of a high-pressure oil-free piston machine is 35MPa, the sealing material replacement cycle is generally about 500h. When applied to high-density rocket launch missions, the frequent replacement of sealing materials will have a certain impact on the rocket's high-density launch process.

[0009] When the rocket system requires high-pressure 45MPa compressed air, the traditional compressed air production process can only use oil compression, which cannot achieve online air supply. The external air supply efficiency is low and it is difficult to meet the needs of high-density test and launch missions. Summary of the Invention

[0010] In order to solve the above technical problems, the present invention provides a high-pressure 45MPa compressed air online oil-free production system and method with long service life, high gas production pressure, high degree of automation, remote control and oil-free compression.

[0011] The present invention discloses an online oil-free production system for high-pressure 45MPa compressed air, comprising a medium-pressure oil-free compression device, the medium-pressure oil-free compression device being used to compress free-state air to medium pressure, thereby providing an air source of a certain pressure and flow rate for a rear-end device; a drying and purification device, the drying and purification device being used to filter and adsorption-dry the medium-pressure gas compressed by the medium-pressure oil-free compression device, thereby providing clean dry air for the rear-end device; a buffer device, the buffer device being used to buffer the medium-pressure air filtered and dried by the drying and purification device, thereby providing an air source with a stable air pressure for the rear-end device; a boosting device, the boosting device being used to perform secondary boosting on the medium-pressure air in the buffer device, thereby providing a high-pressure 45MPa air source with a certain flow rate for the downstream device; and a control system, the control system being used to distribute power to each device and perform process control according to a predetermined program, monitor and display the operating parameters of each device, and upload the parameters to a central control room; the medium-pressure oil-free compression device, the drying and purification device, the buffer device, and the boosting device being sequentially connected in series through a pipeline, thereby online oil-free compressing the free-state air into finished gas with a pressure of 45MPa.

[0012] The present invention provides a high-pressure 45MPa compressed air online oil-free production system, wherein the medium-pressure oil-free compression device is a medium-pressure oil-free piston machine, and the medium-pressure oil-free piston machine is connected to a drying and purification device through a pipeline.

[0013] The present invention provides a high-pressure 45MPa compressed air online oil-free production system, wherein the buffer device is a buffer tank, the buffer tank is connected to the drying and purification device through a pipeline, and the boosting device is connected to the buffer tank through a pipeline.

[0014] The present invention provides an online oil-free system for producing high-pressure 45MPa compressed air, wherein the boosting device is a diaphragm compressor, and the diaphragm compressor is connected to a buffer tank through a pipeline.

[0015] The present invention provides a high-pressure 45MPa compressed air online oil-free production system, wherein the control system establishes information interaction with a medium-pressure oil-free piston machine, a drying and purification device, a buffer tank and a diaphragm compressor, and monitors and controls them.

[0016] The present invention provides an online oil-free system for producing high-pressure 45MPa compressed air, wherein the diameter of the finished gas dust particles is ≤14μm and the solid particle concentration is <5mg / m 3 , dew point ≤-60℃, oil content: ≤0.1mg / m 3 .

[0017] The present invention provides a method for using a high-pressure 45MPa compressed air online oil-free production system:

[0018] (1) Start the control system, distribute power to the medium-pressure oil-free piston machine, drying and purification device, buffer tank and diaphragm compressor, and initialize each device according to the predetermined program;

[0019] (2) Start the medium-pressure oil-free piston machine to compress the free-state air to medium pressure, so that the air pressure reaches a maximum of 10 MPa, and output it to the drying and purification device;

[0020] (3) The drying and purification device absorbs, dries and filters the air to remove moisture from the air and remove larger dust particles and solid particles in the air, so that the dew point of the treated air is ≤-60℃, the diameter of dust particles is ≤14μm, and the concentration of solid particles is <5mg / m 3 , and then output to the buffer tank;

[0021] (4) The buffer tank receives the clean dry air processed by the drying and purification device, buffers it, and stabilizes the air pressure;

[0022] (5) The diaphragm compressor performs secondary boosting on the medium-pressure air in the buffer tank, raising its pressure to a maximum of 45 MPa, and delivers high-pressure finished gas to the downstream;

[0023] (6) During the entire process, the control system monitors the operating parameters of the medium-pressure oil-free piston machine, drying and purification device, buffer tank and diaphragm compressor in real time, and uploads these parameters to the central control room.

[0024] The present invention discloses a method for using a high-pressure 45MPa online oil-free compressed air production system. If the control system detects that the medium-pressure air pressure after a primary pressurization of a medium-pressure oil-free piston machine is less than or equal to 10MPa and the temperature is less than 40°C, the system is transported to a drying and purification device for drying and purification. Otherwise, the system is shut down and an alarm is issued, and a fault signal is uploaded to a central control room. The medium-pressure oil-free piston machine is repaired and operation is resumed after the fault is eliminated.

[0025] If the control system detects that the dew point of the medium-pressure air processed by the drying and purification device is ≤-60℃, the diameter of the dust particles is ≤14μm and the solid particle concentration is <5mg / m 3, it is transported to the buffer tank for buffering, and then transported to the diaphragm compressor for secondary pressurization after buffering. Otherwise, the operating parameters of the drying and purification device are adjusted. If the standards are not met after adjustment, the device will be shut down and an alarm will be issued, and the fault signal will be uploaded to the central control room. The drying and purification device will be repaired and the operation will be resumed after the fault is eliminated.

[0026] The present invention provides a method for using a high-pressure 45MPa compressed air online oil-free production system. If the control system detects that the pressure of the finished gas after secondary pressurization of the diaphragm compressor is ≤45MPa and the temperature is ≤40°C, the finished gas is transported to the downstream. Otherwise, the system is shut down and an alarm is issued, and a fault signal is uploaded to a central control room. The diaphragm compressor is repaired and operation is resumed after the fault is eliminated.

[0027] The present invention provides an online oil-free method for producing high-pressure 45MPa compressed air, comprising the following steps:

[0028] (1) The free-state air is pressurized once to obtain medium-pressure air with a maximum pressure of 10 MPa;

[0029] (2) Drying and purifying the medium-pressure air;

[0030] (3) buffering the dried and purified medium-pressure air;

[0031] (4) The buffered medium-pressure air is pressurized for a second time to obtain a finished gas with a maximum pressure of 45 MPa.

[0032] The difference between the present invention and the prior art lies in that: the high-pressure 45MPa compressed air production system of the present invention first uses a medium-pressure oil-free piston machine to perform oil-free compression on normal-pressure gas, and then dries, filters, dehumidifies and removes impurities on the compressed medium-pressure air to filter out medium-pressure clean air, and then stabilizes the medium-pressure clean air through a buffer tank, and finally inputs it into a diaphragm compressor for secondary pressurization, compressing the medium-pressure clean air into high-pressure 45MPa finished gas to meet the requirements of rocket testing and launch, and the entire compression process control system always monitors each device in real time through various sensors, and transmits data to the central control room for self-adjustment and remote control.

[0033] The high-pressure 45MPa compressed air online oil-free production system of the present invention has at least the following beneficial effects:

[0034] (1) This system does not require degreasing of the air. Eliminating the degreasing step not only saves costs but also enables online gas supply. It is simple and convenient to use and improves gas production efficiency. In addition, the sealing materials (piston rings and packings, etc.) used in the compression device and the booster device have a certain service life. The exhaust pressure of the medium-pressure oil-free compression device is lower than that of the high-pressure oil-free compression device, and the service life of the sealing material is relatively long, which further saves costs.

[0035] (2) The control system monitors the system in real time through various sensors, stores the data information in the internal memory, and sends it to the central control room to remind the staff to perform relevant operations, so as to achieve remote and on-site "one-button" start and stop.

[0036] The present invention will be further described below with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 This is a schematic diagram of an online oil-free production system for high-pressure 45MPa compressed air according to the present invention.

[0038] Reference numerals:

[0039] 01-Medium-pressure oil-free piston machine; 02-Drying and purification device; 03-Buffer tank; 04-Diaphragm compressor; 05-Control system. DETAILED DESCRIPTION

[0040] like Figure 1 As shown, the present invention provides an online oil-free production system for high-pressure 45MPa compressed air, including a medium-pressure oil-free compression device, which is used to compress free-state air to medium pressure and provide an air source with a certain pressure and flow rate for the back-end device; a drying and purification device 02, which is used to filter and adsorb and dry the medium-pressure gas compressed by the medium-pressure oil-free compression device, and provide clean dry air for the back-end device; a buffer device, which is used to buffer the medium-pressure air filtered and dried by the drying and purification device 02, and provide an air source with a stable air pressure for the back-end device; a boosting device, which is used to perform secondary boosting on the medium-pressure air in the buffer device, and provide a certain flow rate of high-pressure 45MPa air for the downstream; a control system 05, which is used to distribute power to each device and perform process control according to a predetermined program, monitor and display the operating parameters of each device, and upload the parameters to the central control room; the medium-pressure oil-free compression device, the drying and purification device 02, the buffer device and the boosting device are connected in series in sequence through pipelines to oil-free compress the free-state air online into a finished gas with a pressure of 45MPa.

[0041] The high-pressure 45MPa compressed air production system of the present invention first uses a medium-pressure oil-free compression device to compress the external air (i.e., free-state air), and compresses it into medium-pressure air with stable flow and pressure, thereby continuously supplying air to the back-end device. Such a setting has multiple advantages. First, there is no need to deoil the air. Eliminating the deoiling step is beneficial to cost saving, and it can also realize online air supply. It is simple and convenient to use and improves the efficiency of gas production. Second, since the rocket test and launch process has high requirements on the quality of the gas medium, and the sealing materials (piston rings and fillers, etc.) used for compression in the compression device have a certain service life, and the higher the exhaust pressure of the compression device, the shorter the replacement cycle. In order to meet the demand, it is necessary to regularly replace the sealing materials in the compression device. Since the exhaust pressure of the medium-pressure oil-free compression device is small compared to the high-pressure oil-free compression device, the sealing material has a relatively long service life, thereby further saving expenses.

[0042] The diameter of the finished gas dust particles is ≤14μm, and the solid particle concentration is <5mg / m 3 , dew point ≤-60℃, oil content: ≤0.1mg / m 3 .

[0043] The drying and purification device 02 is connected to the back of the medium-pressure oil-free compression device through a pipeline seal to dry and purify the medium-pressure air delivered by the medium-pressure oil-free compression device. On the one hand, it removes moisture from the air to ensure that the dew point of the finished gas at normal pressure is ≤-60°C; on the other hand, it removes solid impurities (such as dust particles, metal chips, etc.) in the air to meet the requirements of dust particle diameter ≤14μm and solid particle concentration <5mg / m 3 On the other hand, although the medium pressure oil-free compression device is oil-free compression, there may still be a very small amount of oil. The drying and purification device 02 can further remove it to meet the oil content of the finished gas ≤ 0.1mg / m 3 requirements.

[0044] The buffer device is connected to the drying and purification device 02 through a pipeline seal. The buffer device stabilizes the flow of clean air processed by the drying and purification device 02 and reduces pressure fluctuations, which helps the back-end equipment work more efficiently. The specific functions are as follows:

[0045] Stable airflow: During system operation, gas flow rate and pressure may fluctuate. For example, during the intake and exhaust processes of a compressor, the gas flow rate is not constant. A buffer device can store a certain amount of gas. When the gas flow increases, it absorbs the excess gas. When the gas flow decreases, it releases the stored gas, thus stabilizing the airflow and preventing the impact of airflow fluctuations on subsequent equipment, thus ensuring stable system operation.

[0046] Reduce pressure fluctuations: Due to the operating characteristics of the compressor, the discharge gas pressure will fluctuate to a certain extent. A buffer device can mitigate this pressure fluctuation, acting like a pressure regulator, smoothing out pressure changes. This helps protect downstream equipment, such as boosters, by preventing premature damage caused by frequent pressure fluctuations and extending equipment life.

[0047] The booster is sealed and connected to the buffer via a pipe. The buffer delivers stable clean air to the booster for secondary boosting, boosting the intermediate-pressure clean air to the high-pressure 45MPa finished gas required for high-density rocket launches. This continuous supply ensures smooth launches. This overcomes the traditional 45MPa high-pressure finished gas production process, which relies solely on oil compression and lacks online gas supply, and improves gas supply efficiency.

[0048] The control system 05 establishes information interaction with the medium-pressure oil-free compression device, the drying and purification device 02, the buffer device and the boosting device, and monitors and controls them.

[0049] The control system 05 is electrically connected to the medium-pressure oil-free compression device, the drying and purification device 02, the buffer device, and the booster device through wires to establish information exchange. The control system 05 includes a variety of sensors, such as pressure sensors, flow sensors, temperature sensors, dew point sensors, particle concentration sensors, oil content sensors, vibration sensors, etc. The control system 05 monitors each device in real time through various sensors and displays relevant parameters on the display screen. The sensors and monitoring methods are as follows:

[0050] Pressure sensors are installed at the outlet of the medium-pressure oil-free compressor, the inlet and outlet of the buffer device, and the inlet and outlet of the booster device. They monitor the gas pressure at each stage in real time, converting the pressure signal into an electrical signal and transmitting it to the control system 05. For example, at the outlet of the medium-pressure oil-free compressor, the actual pressure of the compressed medium-pressure gas is fed back, allowing the control system 05 to determine whether it has reached the predetermined pressure value. At the outlet of the booster device, the pressure of the final high-pressure gas output, 45 MPa, is monitored to ensure that it remains within the specified range.

[0051] Flow sensors are installed at the outlets of the medium-pressure oil-free compressor and the booster. They measure gas flow and provide information to the control system 05, ensuring that the system delivers finished gas at the predetermined flow rate. They also measure the cooling water flow in the cooling systems of the medium-pressure oil-free compressor and booster, ensuring that the compressed gas temperature meets the required level. For example, based on the feedback from the flow sensors, the control system 05 can adjust the operating parameters of the medium-pressure oil-free compressor and booster to ensure that the output air flow meets backend requirements.

[0052] Temperature sensors are installed at outlets of medium-pressure oil-free compressors and boosters. They detect gas temperature, which significantly impacts gas properties and equipment operation. Temperature monitoring at the outlets of medium-pressure oil-free compressors and boosters determines whether the gas has reached a temperature of ≤40°C after cooling. If this is not the case, the control system 05 issues a shutdown command and sends an alarm to the outside world. A fault signal is also uploaded to the central control room for inspection by workers. In boosters, temperature sensors help the control system 05 monitor temperature changes during the boosting process to prevent excessive temperatures from impacting equipment performance and gas quality.

[0053] Dew point sensor: Installed at the outlet of drying and purification unit 02. It primarily monitors the dew point of the finished gas to ensure it remains at -60°C or lower at atmospheric pressure, ensuring that the gas's dryness meets back-end process requirements. If the dew point falls below the standard, control system 05 can adjust the operating parameters of drying and purification unit 02, such as increasing the adsorption time or replacing the adsorbent.

[0054] Particle concentration sensor: Installed at the outlet of drying and purification device 02 and other locations. Used to detect the dust particle concentration and solid particle concentration in the finished gas, ensuring that the dust particle diameter is ≤14μm and the solid particle concentration is <5mg / m 3 , preventing impurities from affecting the normal operation of back-end equipment and product quality. When it is detected that the particle concentration exceeds the standard, the control system 05 can issue an alarm and take corresponding measures, such as strengthening filtration.

[0055] Control of the medium-pressure oil-free compressor: Control system 05 compares the outlet gas pressure and flow signals from the medium-pressure oil-free compressor, as fed back by pressure and flow sensors, with predetermined pressure and flow parameters. If the actual pressure or flow falls below the set value, control system 05 adjusts the operating parameters of the medium-pressure oil-free compressor to ensure stable output.

[0056] Control of Drying and Purifying Device 02: Based on signals from the dew point sensor and the particle concentration sensor, Control System 05 determines the treatment effectiveness of Drying and Purifying Device 02. If the dew point does not meet the standard, Control System 05 can control the adsorbent regeneration cycle or replace the adsorbent. If the particle concentration exceeds the standard, Control System 05 will alarm and upload the fault signal to the central control room, prompting workers to replace the filter in Drying and Purifying Device 02 to ensure that the output gas meets the requirements of cleanliness and dryness.

[0057] Control of the buffer device: A pressure sensor monitors pressure changes within the buffer device. When the pressure is too high or too low, the control system 05 controls the medium-pressure oil-free compressor to adjust the gas input, maintaining a stable pressure within the buffer device and providing a stable gas source for the downstream booster device.

[0058] Control of the booster: Based on the inlet and outlet gas pressure and flow signals from the pressure and flow sensors, Control System 05 adjusts the booster's operating parameters to ensure the output high-pressure gas reaches a maximum pressure of 45 MPa and the flow rate meets downstream demand. Furthermore, based on the temperature sensor signals, if the gas temperature becomes too high during the boost process, Control System 05 issues a shutdown command to each device, alerts the outside world, and transmits a fault signal to the central control room for inspection.

[0059] In addition to real-time monitoring of each device, the control device can also perform self-diagnosis and adjustment of the system, as follows:

[0060] Self-diagnosis: Control System 05 continuously monitors the signals from each sensor. When a sensor malfunctions, its output signal may exhibit anomalies, such as loss of signal or exceeding the normal operating range. For example, if the output value of a pressure sensor suddenly drops to zero or exceeds the normal operating pressure range of the equipment, Control System 05 will determine that the pressure sensor may be faulty and store the fault information as a fault code in internal memory. It will also send an alarm to the central control room, prompting staff to conduct inspection and repairs, enabling remote and on-site "one-touch" start and stop operations.

[0061] Self-regulation: When a sensor's signal exhibits a slight deviation that does not affect basic system operation, Control System 05 can employ fault protection strategies or adaptive adjustments. For example, if a temperature sensor's signal exhibits a certain deviation, but the deviation is within an acceptable range, Control System 05 may replace the faulty sensor's signal with historical temperature data or an approximate temperature value calculated based on other relevant sensor signals, maintaining system operation. It may also issue an early warning message when appropriate, prompting personnel to calibrate or replace the sensor, thereby ensuring stable system operation.

[0062] The present invention provides a high-pressure 45MPa compressed air online oil-free production system, wherein the medium-pressure oil-free compression device is a medium-pressure oil-free piston machine 01, and the medium-pressure oil-free piston machine 01 is connected to the drying and purification device 02 through a pipeline.

[0063] The medium-pressure oil-free compression device uses a medium-pressure oil-free piston machine 01, which has a rated exhaust pressure of 10MPa. It can stably boost the free-state air to 10MPa, and is equipped with a dedicated water cooling system inside. The system cools the boosted medium-pressure air to prevent the medium-pressure air temperature from being too high and affecting the back-end equipment and air quality. Since the medium-pressure oil-free piston machine 01 has a low boost amplitude and stable air pressure, and its internal sealing material has a long service life (generally not less than 2000h), compared with previous high-pressure oil-free piston machines, the medium-pressure oil-free piston machine 01 greatly extends the service life of the sealing material, thereby saving costs. In addition, during the gas production process, since the real-time detection of the oil content in the air is difficult and has low accuracy, the medium-pressure oil-free piston machine 01 can meet the needs of specific scenarios for medium-pressure and oil-free compressed air, ensuring that the finished gas can reach an oil content of ≤0.1mg / m 3 standards to ensure air quality.

[0064] During operation, the medium-pressure oil-free piston engine 01 draws in free-state air from the air inlet passage and pressurizes it, and then discharges the pressurized medium-pressure air from the exhaust passage through a pipeline into the drying and purification device 02.

[0065] Air filters are installed at the air inlet and exhaust ports of the drying and purification device 02. The air filters are mainly used to remove solid impurities (such as dust particles, non-metallic chips, etc.) in the medium-pressure air, making the subsequent gas cleaner and providing more suitable air intake conditions for the operation of the drying and purification device 02. Ultimately, the diameter of the dust particles in the finished gas is guaranteed to be ≤14μm and the solid particle concentration is <5mg / m 3 .

[0066] The medium-pressure gas is first filtered through an air filter, then adsorbed and dried, and then finally filtered. The adsorbent's adsorption characteristics for moisture are used to remove moisture from the gas, thereby providing clean, dry air for the back-end device. Finally, the filtered and dried medium-pressure air is transported to the buffer device through a pipeline.

[0067] The drying and purification device 02 can adopt a double-tower dryer or other equipment with the same effect, so that the dryer can perform adsorption drying in one tower while the other tower regenerates the adsorbent, ensuring the continuity and stability of the drying work, thereby enhancing the working efficiency of the high-pressure 45MPa compressed air production system.

[0068] The present invention provides a high-pressure 45MPa compressed air online oil-free production system, wherein the buffer device is a buffer tank 03, the buffer tank 03 is connected to the drying and purification device 02 through a pipeline, and the boosting device is connected to the buffer tank 03 through a pipeline.

[0069] The buffer tank 03 is connected to the drying and purification device 02 through a pipeline. It is mainly used to stabilize the pressure and flow of the clean air after filtration and drying. Since it can temporarily store gas, the medium-pressure clean air is buffered in it, providing a stable air source for the back-end device, ensuring that subsequent back-end equipment such as the booster device can operate under relatively stable air pressure conditions, ensuring that the high-pressure 45MPa compressed air production system runs more smoothly.

[0070] The present invention provides a high-pressure 45MPa compressed air online oil-free production system, wherein the boosting device is a diaphragm compressor 04, and the diaphragm compressor 04 is connected to the buffer tank 03 through a pipeline.

[0071] The diaphragm compressor 04 is connected to the buffer tank 03 through a pipeline, and is mainly used to perform secondary pressurization on the clean air in the buffer tank 03, and then compress the medium-pressure air to a high pressure of 45MPa that meets the requirements of rocket test and launch.

[0072] The diaphragm compressor 04 used in this high-pressure 45MPa compressed air production system is a specially constructed positive displacement compressor. During the compression process, the medium does not come into contact with any lubricant, resulting in extremely high-quality compressed gas. Its high process index and volumetric efficiency enable a high compression ratio, and its internal wearing parts have a long maintenance and replacement cycle, generally exceeding 4000 hours, contributing to cost savings. Furthermore, a dedicated water-cooling system is installed within diaphragm compressor 04 to cool the 45MPa finished gas after secondary pressurization, preventing excessively high finished gas temperatures from affecting downstream equipment.

[0073] A combination of medium-pressure oil-free piston machine 01 and diaphragm compressor 04 is adopted. After the front-end medium-pressure oil-free piston machine 01 compresses the normal-pressure air to medium pressure, the rear-end diaphragm compressor 04 can easily compress the medium-pressure air to a high-pressure 45MPa. On the basis of meeting the rocket test and launch standards, it can also save costs and extend the service life of the high-pressure 45MPa compressed air production system.

[0074] The control system 05 establishes information interaction with the medium-pressure oil-free piston machine 01, the drying and purification device 02, the buffer tank 03 and the diaphragm compressor 04, and monitors and controls them to ensure the stable operation of the high-pressure 45MPa compressed air production system.

[0075] It should be noted that in order to demonstrate the technical effect of this system, a long-term operation experiment was conducted. After 2000 hours of continuous operation of the high-pressure 45MPa compressed air production system configuration of the present invention, the finished gas was tested:

[0076] Oil content detection: ISO8573-2:2007 "Compressed air part 2: test method for suspended oil content" is used for detection, and the oil content of finished gas is stable at 0.05-0.08mg / m3 Range, better than ISO8573-1:2010Class1 standard (oil content ≤ 0.1mg / m 3 ).

[0077] Dust particle detection: A laser particle size analyzer was used to detect the diameter of dust particles. The results showed that 99.9% of the particles had a diameter of ≤10μm, meeting the index requirement that the diameter of finished gas dust particles should be ≤14μm.

[0078] Solid particle concentration detection: The solid particle concentration is detected by weight method or optical particle counter method. The solid particle concentration of finished gas is stable at 3mg / m 3 About 5mg / m3, which is much lower than the solid particle concentration of finished gas <5mg / m3 3 indicator requirements.

[0079] The following is a method for using a high-pressure 45MPa compressed air online oil-free production system of the present invention:

[0080] (1) Startup phase: Start the control system 05, distribute power to the medium-pressure oil-free piston machine 01, the drying and purification device 02, the buffer tank 03 and the diaphragm compressor 04, and initialize each device according to the predetermined program to prepare for the work.

[0081] (2) Air compression stage: The medium-pressure oil-free piston machine 01 is turned on to compress the free-state air to medium pressure, so that the air pressure reaches a maximum of 10 MPa, and is cooled by the internal water cooling system and then output to the drying and purification device 02;

[0082] (3) Drying and purification stage: Drying and purification device 02 performs adsorption drying and filtration on the medium-pressure air to remove moisture from the air and remove larger dust particles and solid particles in the air, so that the diameter of the treated air dust particles is ≤14μm, the dew point is ≤-60℃, and the solid particle concentration is <5mg / m 3 , and then output to buffer tank 03;

[0083] (4) Buffering stage: The buffer tank 03 receives the clean dry air processed by the drying and purification device 02, buffers it, stabilizes the air pressure, and ensures that the air pressure output to the diaphragm compressor 04 is within the fluctuation range;

[0084] (5) Pressurization stage: The diaphragm compressor 04 performs secondary pressurization on the medium-pressure air in the buffer tank 03, raising its pressure to a maximum of 45 MPa and at a pressure of ≥360 Nm 3 / h flow rate to transport high-pressure finished gas to the downstream;

[0085] (6) Control and Monitoring Phase: Throughout the entire process, the control system 05 monitors the operating parameters of the medium-pressure oil-free piston machine 01, drying and purification device 02, buffer tank 03, and diaphragm compressor 04 in real time, including but not limited to pressure, flow, temperature, dew point, and vibration, and uploads these parameters to the central control room. If the operating parameters exceed the preset range, the control system 05 automatically adjusts the operating status of each device to ensure stable system operation and produce qualified high-pressure 45MPa finished gas.

[0086] The method for using the high-pressure 45MPa compressed air online oil-free production system of the present invention is as follows:

[0087] Step 1: If the control system 05 detects that the medium-pressure air pressure after the medium-pressure oil-free piston machine 01 is pressurized once and the pressure is ≤10MPa and the temperature is <40℃, it will be transported to the drying and purification device 02 for drying and purification treatment. Otherwise, the machine will be shut down and an alarm will be uploaded to the central control room. Workers will go to the site to repair the medium-pressure oil-free piston machine 01 and resume operation after eliminating the fault. Even if the air pressurized by the medium-pressure oil-free piston machine 01 does not reach 10MPa at the beginning, it will gradually rise to 10MPa as the air continues to accumulate in the pipeline or equipment.

[0088] Step 2: If the control system 05 detects that the medium-pressure air treated by the drying and purification device 02 has a dew point of ≤-60°C, a dust particle diameter of ≤14μm and a solid particle concentration of <5mg / m 3 , it is transported to the buffer tank 03 for buffering, and then transported to the diaphragm compressor 04 for secondary pressurization. Otherwise, the system will shut down and alarm and upload the fault signal to the central control room. Workers will go to the site to repair the drying and purification device 02 and resume operation after eliminating the fault.

[0089] Step 3: If the control system 05 detects that the pressure of the finished gas after the secondary pressurization of the diaphragm compressor 04 is ≤45MPa and the temperature is ≤40℃, the finished gas will be transported to the downstream, otherwise the shutdown alarm will be issued and the fault signal will be uploaded to the central control room. Workers will go to the site to repair the diaphragm compressor 04 and resume operation after eliminating the fault. Similarly, as the diaphragm compressor 04 continues to perform secondary pressurization, the finished gas pressure will continue to accumulate in the pipeline or equipment and will gradually rise to 45MPa.

[0090] The present invention provides an online oil-free method for producing high-pressure 45MPa compressed air, comprising the following steps:

[0091] (1) The free-state air is pressurized once to obtain medium-pressure air with a maximum pressure of 10 MPa;

[0092] (2) Drying and purifying the medium-pressure air;

[0093] (3) buffering the dried and purified medium-pressure air;

[0094] (4) The buffered medium-pressure air is pressurized for a second time to obtain a finished gas with a maximum pressure of 45 MPa.

[0095] The above-mentioned method for using the high-pressure 45MPa compressed air online oil-free production system is a specific implementation method for realizing the high-pressure 45MPa compressed air online oil-free production method.

[0096] It should be noted that the directions or positional relationships indicated by terms such as "center", "up", "down", "front", "back", "left", "right", and "middle" are based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, they should not be understood as limiting the present invention.

[0097] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "connected" and "connection" should be understood in a broad sense. For example, they can refer to fixed connection, detachable connection, or integral connection; mechanical connection, electrical connection; direct connection, or indirect connection through an intermediary. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0098] The embodiments described above are merely descriptions of preferred implementations of the present invention and are not intended to limit the scope of the present invention. Without departing from the spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by ordinary technicians in this field should fall within the scope of protection determined by the claims of the present invention.

Claims

1. A high-pressure 45MPa compressed air online oil-free production system, characterized by: It includes a medium-pressure oil-free compression device, which is used to compress free-state air to medium pressure and provide an air source with a certain pressure and flow rate for the back-end device; A drying and purification device, which is used to filter and adsorb and dry the medium-pressure gas compressed by the medium-pressure oil-free compression device to provide clean dry air for the back-end device; A buffer device, which is used to buffer the medium-pressure air after being filtered and dried by the drying and purification device, and provide an air source with stable air pressure for the back-end device; A booster device, which is used to perform secondary boosting on the medium-pressure air in the buffer device to provide a certain flow of high-pressure 45MPa air to the downstream; A control system, which is used to distribute power to each device and control the process according to a predetermined program, monitor and display the operating parameters of each device, and upload the parameters to the central control room; The medium-pressure oil-free compression device, drying and purification device, buffer device and boosting device are sequentially connected in series through pipelines to compress the free-state air into finished gas with a pressure of 45 MPa online without oil.

2. The high-pressure 45MPa compressed air online oil-free production system according to claim 1, characterized in that: The medium-pressure oil-free compression device is a medium-pressure oil-free piston machine, and the medium-pressure oil-free piston machine is connected to the drying and purification device through a pipeline.

3. The high-pressure 45MPa compressed air online oil-free production system according to claim 2, characterized in that: The buffer device is a buffer tank, which is connected to the drying and purification device through a pipeline, and the boosting device is connected to the buffer tank through a pipeline.

4. The high-pressure 45MPa compressed air online oil-free production system according to claim 3, characterized in that: The boosting device is a diaphragm compressor, and the diaphragm compressor is connected to the buffer tank through a pipeline.

5. The high-pressure 45MPa compressed air online oil-free production system according to claim 4, characterized in that: The control system establishes information interaction with the medium-pressure oil-free piston machine, the drying and purification device, the buffer tank and the diaphragm compressor respectively, and monitors and controls them.

6. The high-pressure 45MPa compressed air online oil-free production system according to claim 5, characterized in that: The diameter of the finished gas dust particles is ≤14μm, and the solid particle concentration is <5mg / m 3 , dew point ≤-60℃, oil content: ≤0.1mg / m 3 .

7. A method for using the high-pressure 45 MPa compressed air online oil-free production system according to any one of claims 1 to 6: (1) Start the control system, distribute power to the medium-pressure oil-free piston machine, drying and purification device, buffer tank and diaphragm compressor, and initialize each device according to the predetermined program; (2) Start the medium-pressure oil-free piston machine to compress the free-state air to medium pressure, so that the air pressure reaches a maximum of 10 MPa, and output it to the drying and purification device; (3) The drying and purification device absorbs, dries and filters the air to remove moisture from the air and remove larger dust particles and solid particles in the air, so that the dew point of the treated air is ≤-60℃, the diameter of dust particles is ≤14μm, and the concentration of solid particles is <5mg / m 3 , and then output to the buffer tank; (4) The buffer tank receives the clean dry air processed by the drying and purification device, buffers it, and stabilizes the air pressure; (5) The diaphragm compressor performs secondary boosting on the medium-pressure air in the buffer tank, raising its pressure to a maximum of 45 MPa, and delivers high-pressure finished gas to the downstream; (6) During the entire process, the control system monitors the operating parameters of the medium-pressure oil-free piston machine, drying and purification device, buffer tank and diaphragm compressor in real time, and uploads these parameters to the central control room.

8. The method for using the high-pressure 45 MPa compressed air online oil-free production system according to claim 7, characterized in that: If the control system detects that the medium-pressure air pressure after the medium-pressure oil-free piston machine is ≤10MPa and the temperature is <40℃, it will be sent to the air filter for drying and purification. Otherwise, the machine will stop and alarm and upload the fault signal to the central control room. The medium-pressure oil-free piston machine will be repaired and the operation will be resumed after the fault is eliminated. If the control system detects that the dew point of the medium-pressure air processed by the drying and purification device is ≤-60℃, the diameter of the dust particles is ≤14μm and the solid particle concentration is <5mg / m 3 , it is transported to the buffer tank for buffering, and then transported to the diaphragm compressor for secondary pressurization after buffering. Otherwise, the operating parameters of the drying and purification device are adjusted. If the standards are not met after adjustment, the device will be shut down and an alarm will be issued, and the fault signal will be uploaded to the central control room. The drying and purification device will be repaired and the operation will be resumed after the fault is eliminated.

9. The method for using the high-pressure 45 MPa compressed air online oil-free production system according to claim 8, characterized in that: If the control system detects that the pressure of the finished gas after the secondary pressurization of the diaphragm compressor is ≤45MPa and the temperature is ≤40℃, the finished gas will be transported to the downstream. Otherwise, the system will shut down and alarm and upload the fault signal to the central control room. The diaphragm compressor will be repaired and the operation will be resumed after the fault is eliminated.

10. A method for producing high-pressure 45MPa compressed air online without oil, characterized in that The following steps are involved: (1) The free-state air is pressurized once to obtain medium-pressure air with a maximum pressure of 10 MPa; (2) Drying and purifying the medium-pressure air; (3) buffering the dried and purified medium-pressure air; (4) The buffered medium-pressure air is pressurized for a second time to obtain a finished gas with a maximum pressure of 45 MPa.

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