Energy Efficient Air Compressor System

Abstract

A system and method for compressing a quantity of air is proposed. The air compressor system and method comprises an air compressor for compressing a quantity of air, a supply air fan for supplying air to maintain a pressure set point at the inlet of the compressor, and a static pressure sensor configured to detect the static pressure of the inlet of the compressor. The embodiment also includes a variable frequency drive serving the supply air fan and operable to modulate the speed of the fan to maintain the static pressure at the inlet of the compressor at a set point. An air pressure regulator valve is provided in connection with and operable to regulate the air pressure of the quantity of air. An air pressure receiver stores air to minimize pressure fluctuations. A dryer and air filter are located upstream of said air compressor in embodiments to save energy.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61 / 824,067 filed on May 16, 2013.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT[0002]Not ApplicableREFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX[0003]Not ApplicableBACKGROUND OF THE INVENTION[0004]1. Technical Field[0005]The disclosed embodiments generally relate to air compressor systems and, more particularly, to air compressors used in industrial manufacturing plants, instruments, and other applications.[0006]2. Description of the Related Art[0007]An air compressor system decreases the volume and increases the pressure of a quantity of air by mechanical means. Compressed air has a lot of potential energy because air expands rapidly upon the removal of external pressure. The force of compressed air can be used to power tools and devices that use air.[0008]FIG. 1 is an illustration of the comp...

AI Technical Summary

Benefits of technology

The patent text describes a system for compressing air using an air compressor, a supply fan, and a static pressure sensor. The system also includes an air pressure regulator valve and an air pressure receiver for storing air to minimize pressure fluctuations. The compressor can be lubricated or lubricant-free, and the system may also include an air separator, lubricant cooler, filters, and a dryer. The technical effects of the patent include higher energy savings, improved air quality, and reduced noise levels.

Problems solved by technology

Since air is often saturated after passing through air filter 118, any temperature drop along the pipe has the potential to cause condensation (and thus create issues during industry processes).

First, the compressor efficiency is low due to the relatively high temperature and presence of excessive moisture.

This can cause up to 6% more compressor power energy consumption.

The dryer and after-cooler also consume as much as 15% of the total compressor power.

Due to the low compressed air temperatures, the compressor efficiency is also low.

However, at the current time there is no known method or system which accomplishes this objective.

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