Dehumidification and energy-saving system at the air inlet end of air compressor

Abstract

The present invention provides an air compressor intake end dehumidification and energy-saving system, characterized by providing three air flow channels: a first air flow channel, a second air flow channel, and a third air flow channel. The first air flow channel introduces external air into the air compressor, while the second air flow channel uses the air compressor's aftercooler and oil cooler to extract heat energy through exhaust or water circulation. The first and second air flow channels are arranged side by side for a section. A dehumidifying wheel of a dehumidifying device is arranged on the two air flow channels, the evaporator of a heat pump system is arranged in the first air flow channel, and the condenser and refrigerant compressor of the heat pump system are arranged in the second air flow channel. The first air flow channel provides dehumidified air to the air compressor, and the heat energy generated by the air compressor during operation is recovered and flows through the second air flow channel to remove moisture adsorbed by the dehumidifying wheel. The third air flow channel connects the upstream and downstream of the first air flow channel and serves as a common bypass channel before startup, ensuring that the air inhaled when the air compressor starts is already dry air.

Description

Technical Field

[0001] The invention relates to an air compressor system, in particular to a dehumidification and energy-saving system at an air compressor intake end. Background Art

[0002] Air compressors are widely used in a wide range of applications, including industry, power generation, and even daily life. They are indispensable. The air compression process generates heat. In typical air compressor systems, the compressor compresses air into high-temperature, high-pressure air that enters the air storage tank, creating high-humidity and high-temperature compressed air. In frequent or large-scale industrial applications, if low-humidity output air is required, a refrigerated dryer is required. For even lower humidity (lower moisture content), an adsorption dryer or other equipment is added. The high-temperature heat generated by the air compressor is typically discharged into the atmosphere via a fan, resulting in energy waste.

[0003] Traditional air compressor systems such as Figure 4 As shown, the air compressor 10 directly sucks in the atmosphere for compression, and then uses the refrigeration dryer 300 and the adsorption dryer 400 to remove moisture. The compressed air is stored in the air storage cylinder 20, and the heat energy of the air compressor is directly discharged into the atmosphere. Summary of the Invention

[0004] In conventional air compressors, high-moisture air enters the compressor directly for compression during operation. The incompressibility of water increases power consumption and easily mixes with the compressor's lubricating oil, causing premature deterioration and shortening the compressor's lifespan. It also removes the lubricating oil from the compressor, increasing subsequent degreasing costs.

[0005] In view of this, the inventors have obtained an air compressor inlet end dehumidification energy-saving system through continuous research and experiments, which shows an effective air compressor inlet end dehumidification function, thereby achieving energy saving and reducing the operating cost of the air compressor.

[0006] The primary objective of the present invention is to provide dehumidified, low-humidity air to the air compressor. Another objective is to utilize the heat generated by the air compressor for the pre-dehumidification process, thereby saving energy and preventing heat waste. A further objective is to prevent moisture from entering the air compressor, thereby reducing power consumption, maintaining the lubricating properties of the lubricating oil, and extending the life of the air compressor. Furthermore, moisture is prevented from dislodging the lubricating oil from the air compressor, thereby reducing degreasing costs.

[0007] Specifically, the present invention provides the following technical solutions:

[0008] A dehumidification and energy-saving system for the air intake end of an air compressor is provided with two air flow channels, a dehumidification device, and a heat pump system; the first air flow channel introduces external air into the air compressor, and the second air flow channel uses the air compressor's aftercooler and oil cooler to extract heat, and the two air flow channels are arranged side by side for a section; the dehumidification wheel of the dehumidification device is arranged on the two air flow channels, and the condenser and refrigerant compressor of the heat pump system are arranged on the second air flow channel; the first air flow channel provides the air compressor with air from which moisture has been removed, and the heat energy generated when the air compressor is working is recovered and flows through the second air flow channel to carry away the moisture adsorbed by the dehumidification wheel.

[0009] Preferably, according to the above-mentioned dehumidification and energy-saving system for the air compressor intake end, an evaporator of a heat pump system is further provided on the first air flow channel, and the evaporator is located upstream of the dehumidification wheel.

[0010] More preferably, according to the above-mentioned dehumidification and energy-saving system for the air compressor air inlet end, the first air flow channel and the second air flow channel share a partition wall in a section where they are arranged side by side.

[0011] More preferably, according to the above-mentioned dehumidification and energy-saving system for the air compressor air inlet end, the dehumidification wheel is arranged on a partition wall shared by the first air flow channel and the second air flow channel.

[0012] More preferably, according to the above-mentioned dehumidification and energy-saving system for the air compressor intake end, the dehumidification wheel rotates at a certain speed so that the moisture adsorbed in the first air flow channel is removed in the second air flow channel.

[0013] More preferably, according to the above-mentioned dehumidification and energy-saving system for the air compressor inlet end, a straight-through heat exchanger is further provided on the first flow channel, and a cross flow channel is provided to the second air flow channel.

[0014] More preferably, according to the above-mentioned dehumidification and energy-saving system for the air compressor inlet end, the direct-cross heat exchanger is arranged between the dehumidification wheel and the inlet of the air compressor.

[0015] More preferably, according to the above-mentioned air compressor inlet end dehumidification and energy-saving system, the direct-cross heat exchanger has two channels, the inlet of one channel is connected to the outside air, and the outlet is connected to the second air flow channel, and the inlet of the other channel is connected to the first air flow channel and the outlet is connected to the inlet of the air compressor.

[0016] More preferably, according to the above-mentioned dehumidification and energy-saving system for the air compressor inlet end, the two channels of the direct-cross heat exchanger are vertical but separated in layers.

[0017] More preferably, according to the above-mentioned dehumidification and energy-saving system for the air compressor intake end, an air storage cylinder is further provided downstream of the aftercooler for storing compressed air.

[0018] More preferably, according to the above-mentioned air compressor inlet end dehumidification and energy-saving system, a third air flow channel is also provided, the third air flow channel is connected to the upstream and downstream of the first air flow channel, and serves as a bypass channel before startup, so that the air inhaled when the air compressor starts is dry air.

[0019] More preferably, according to the above-mentioned air compressor inlet end dehumidification and energy-saving system, the air compressor is a water-cooled air compressor, a hot water heat exchanger is arranged in the second air flow channel, a cooling water heat exchanger is arranged in the first air flow channel, and a cooling water tower is arranged outside the first air flow channel and the second air flow channel.

[0020] The air compressor inlet end dehumidification and energy-saving system of the present invention can utilize the heat generated by the air compressor for front-stage dehumidification, thereby achieving energy saving and preventing waste of heat energy. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a schematic diagram of the composition of the present invention;

[0022] Figure 2 This is a schematic diagram of another technical solution of the present invention.

[0023] Figure 3 This is a schematic diagram of another technical solution for a water-cooled air compressor according to the present invention.

[0024] Figure 4 Schematic diagram of the structure of a traditional air compressor system.

[0025] Among them, 10-air compressor, 101-intake port, 20-air storage cylinder, 30-aftercooler, 31-oil cooler, 301-opening, 40-first air flow channel, 41-inlet, 41a-opening and closing port, 42-partition wall, 43-fan, 44-A compartment, 44b-opening and closing port, 45-B compartment, 46-C compartment, 47-D compartment, 50-second air flow channel, 51-outlet, 52-fan, 52a-fan, 53-F compartment, 54-G compartment, 5 5-H compartment, 56-J compartment, 57-K compartment, 60-dehumidification wheel, 70-evaporator, 80-compressor, 90-condenser, 100-direct cross heat exchanger, 100a-inlet, 100b-X compartment, 100c-Y compartment, 100d-opening and closing port, 100g-opening and closing port, 100j-fan, 300-refrigerated dryer, 400-adsorption dryer, e-third air flow channel, f-hot water heat exchanger, h-cooling water tower, i-cooling water heat exchanger. DETAILED DESCRIPTION

[0026] like Figure 1As shown, the present invention includes an air compressor unit, two air flow channels, a dehumidification device, and a heat pump system. The air compressor unit includes an air compressor 10, an air receiver 20, an aftercooler 30, and an oil cooler 31. The two air flow channels include a first air flow channel 40 and a second air flow channel 50. These two air flow channels 40 and 50 are partially aligned, and a dehumidification wheel 60 is installed in this aligned section. The dehumidification device includes the dehumidification wheel 60. The heat pump system includes an evaporator 70, a refrigerant compressor 80, a condenser 90, and related pipelines.

[0027] The first air flow channel 40 refers to the space between the air inlet 41 and the air compressor 10. Except for the inlet 41, it is generally closed and forms a parallel section with the second air flow channel 50 by a partition wall 42. The evaporator 70, dehumidifier wheel 60, fan 43 and air compressor 10 are arranged in sequence inside the first air flow channel 40. The space is roughly divided into compartment A 44, compartment B 45 and compartment C 46.

[0028] The second air flow channel 50 is generally closed except for the outlet 51 at the front end and the opening 301 near the aftercooler 30 and the oil cooler 31. It forms a parallel section with the first air flow channel 40 by a partition wall 42. The aftercooler 30 and the oil cooler 31, the compressor 80, the condenser 90, the dehumidification wheel 60 and at least one fan 52 are arranged in sequence inside the second air flow channel 50. The space can be roughly divided into the F compartment 53, the G compartment 54, the H compartment 55, the J compartment 56 and the K compartment 57. A fan 52a is provided between the F compartment 53 and the G compartment 54.

[0029] The air compressor 10 is a commonly used device for compressing air, primarily using mechanical energy to compress air for future use. It is not limited to a specific compression method. The air reservoir 20 is used to store air for future use and is a commonly used device with components for air input and output. The aftercooler 30 and oil cooler 31 are devices that transfer compressed air from the air compressor 10 to the air reservoir 20. When the air compressor 10 is operating, the aftercooler 30 and oil cooler 31 gradually reach a high temperature (typically, approximately 80°C to 100°C, but not limited to this).

[0030] During operation, air enters compartment A 44 through inlet 41, condenses water in evaporator 70, and then drains out. The air then flows through evaporator 70 into compartment B 45, where it is further dehumidified by dehumidifier wheel 60. Dehumidifier wheel 60 in this location rotates and enters second air flow channel 50. After entering compartment C 46, the air is guided by fan 43 into intake port 101 of air compressor 10. The primary function of fan 43 is to guide air circulation within first air flow channel 40. After passing through evaporator 70 and dehumidifier wheel 60, a significant amount of moisture (i.e., humidity) is removed from the air, resulting in dry air for compression by air compressor 10.

[0031] During operation, as indicated by the arrows, the hot air in second air flow channel 50 flows from aftercooler 30 and oil cooler 31, and from nearby compartment F 53, through compartment G 54, and then to compartment H 55. After being heated by refrigerant compressor 80 and condenser 90, the hot air enters compartment J 56. The hot air then passes through dehumidifier 60, where it removes moisture and enters compartment K 57, where fan 52 delivers the hot and humid air out of outlet 51. Fan 52a can be positioned between compartment F 53 and compartment G 54. The primary function of fans 52 and 52a is to guide air circulation within second air flow channel 50.

[0032] The operating sequence of the unit is as follows:

[0033] 1. Before the air compressor 10 starts operating, since the aftercooler 30 and the oil cooler 31 are not yet able to provide heat energy, various well-known methods can be used to first provide dry air to the air compressor 10. Alternatively, the following means can be used to provide dry air to the air compressor 10: the evaporator 70, the refrigerant compressor 80, and the condenser 90 are first started to provide the regenerative heat energy required for dehumidification by the dehumidification wheel 60, the opening and closing port 44b of the third air flow channel e is opened, and the inlet 41 is closed at the same time, resulting in a closed cycle of the third air flow channel e, so that dehumidified air can be immediately provided at the initial stage of the operation of the air compressor 10. When the air compressor 10 is started, the opening and closing port 44b is closed, the inlet 41 is opened, and the working state of air flowing through the first air flow channel 40 is restored.

[0034] 2. When the air compressor 10 is started, the heat energy of the aftercooler 30 and the oil cooler 31 is supplied to the regeneration side of the dehumidifier wheel 60. When the air volume and heat are sufficient for the dehumidifier wheel to regenerate, the heat pump is regulated to be an auxiliary heat source.

[0035] 3. When the air compressor 10 is started, the heat energy from the aftercooler 30 and the oil cooler 31 is supplied to the regeneration side of the dehumidifier wheel 60. If the air volume and heat are insufficient for the dehumidifier wheel 60 to regenerate, it is necessary to find another air volume to supplement the regeneration air volume required by the dehumidifier wheel. The heat pump is then regulated to act as an auxiliary heat source.

[0036] 4. Such as Figure 2 As shown, when the air volume needs to be supplemented, a direct heat exchanger 100 (which has stacked components to form air channels in two directions and is a common component, mainly allowing heat energy to be exchanged in two air flow directions) is installed in the flow path within the first air flow channel 40. It is installed between the dehumidifier wheel 60 and the inlet of the air compressor 10; in the other direction of the direct heat exchanger 100, the outside air is guided to flow into the H compartment 55; its main function is to provide air to the second air flow channel 50; as shown in FIG. Figure 2 As shown, the structure includes an air inlet 100a, an X compartment 100b, a Y compartment 100c, and an opening and closing port 100d. A direct-flow heat exchanger 100 is disposed between the X compartment 100b and the Y compartment 100c. When the opening and closing port 100d is open and the fan 52 is operating, outside air is drawn into the X compartment 100b through the direct-flow heat exchanger 100 through the inlet 100a, flows through the direct-flow heat exchanger 100, and then passes through the Y compartment 100c and the opening and closing port 100d before entering the second air flow channel 50. This arrangement is intended to supplement the air flow of the second air flow channel 50. Furthermore, the air downstream of the dehumidifier 60 in the first air flow channel 40 is at a medium temperature. After passing through the direct-flow heat exchanger 100, it is cooled by the air barrier of the cross channel, thereby lowering the temperature of the air delivered to the air compressor 10. At the same time, the temperature of the air introduced through the air inlet 100a will be increased by flowing through the DC heat exchanger 100. The air that intersects the DC heat exchanger 100 is the outside air introduced into the X compartment 100b through the inlet 100a, flows through the DC heat exchanger 100, and then passes through the Y compartment 100c and the opening and closing port 100d to enter the H compartment 55 of the second air flow channel 50.

[0037] The Y compartment 100c is provided with an opening and closing port 100g and a fan 100j. When the temperature of the air in the D compartment 47 before being sucked into the air compressor 10 exceeds the standard inlet temperature of the air compressor 10, the opening and closing port 100g and the fan 100j are opened to increase the amount of air introduced from 100a through the direct cross heat exchanger 100, thereby cooling the air temperature from the C compartment 46 to the D compartment 47.

[0038] The dehumidifier wheel 60 is mounted on or near the partition wall 42 shared by the first air flow channel 40 and the second air flow channel 50, so that the dehumidifier wheel 60 is placed across the first air flow channel 40 and the second air flow channel 50. The rotating dehumidifier wheel 60 absorbs moisture when passing through the first air flow channel 40, and then loses moisture when entering the second air flow channel 50, forming a dry state, and then returns to the first air flow channel 40 to absorb moisture. This process is repeated, continuously removing moisture from the first air flow channel 40.

[0039] The air compressor 10 is a well-known device and can be an air-cooled air compressor or a water-cooled air compressor. If it is an air-cooled air compressor, Figure 1 or Figure 2 If it is a water-cooled air compressor, its structure diagram is as follows: Figure 3 As shown, if applied to a water-cooled air compressor 10, a cooling water heat exchanger i and a hot water heat exchanger f, a cooling water tower h, and associated piping are respectively provided in the first air flow channel 40 and the second air flow channel 50, so as to guide the heat energy of the air compressor 10 to the space 55 for application, and to cool the temperature of the air entering the D compartment 47 into the air compressor 10.

[0040] The present invention first dries, dehumidifies and cools the atmosphere before it enters the air compressor for compression, and recycles the heat energy of the air compressor as heat energy for regeneration of the front-end dehumidification wheel. Compared with the traditional air compressor system, it has at least the following advantages: 1. The power consumption of the air compressor can be reduced by reducing water compression. 2. The water content of the air compressor lubricating oil can be reduced by reducing water compression, slowing down the deterioration of the oil, thereby increasing the life of the air compressor. 3. The amount of air compressor lubricating oil carried out by reducing water compression can be reduced, which relatively reduces the cost of the subsequent oil removal treatment. 4. The power consumption of the entire system can be greatly reduced by recycling the heat energy of the air compressor. 5. With the improvement of the performance of the dehumidification wheel or the application of multiple multi-stage dehumidification wheels and multi-circulation flow channels, this system can replace the refrigeration dryer or adsorption dryer one by one, achieving equipment streamlining and thus reducing equipment costs.

[0041] The above embodiments are only used to illustrate the present invention and to explain the technical features of the present invention, and are not intended to limit the scope of protection of the present invention. Any changes or equivalent arrangements that can be easily completed by those skilled in the art fall within the scope of protection claimed by the present invention.

Claims

1. A dehumidification and energy-saving system for the air inlet end of an air compressor, which is provided with two air flow channels, a dehumidification device, and a heat pump system; a first air flow channel (40) introduces external air into the air compressor (10), and a second air flow channel (50) extracts heat from the aftercooler (30) and the oil cooler (31) of the air compressor (10), and the two air flow channels are arranged side by side for a section; a dehumidification wheel (60) of the dehumidification device is arranged on the two air flow channels, and the dehumidification wheel (60) can rotate so that the dehumidification wheel (60) adsorbs the dehumidification in the first air flow channel (40). Moisture is removed in the second air flow channel (50); a condenser (90) and a refrigerant compressor (80) of the heat pump system are arranged on the second air flow channel (50); an evaporator (70) of the heat pump system is arranged on the first air flow channel (40), and the evaporator (70) is located upstream of the dehumidification wheel (60); the first air flow channel (40) provides air with dehumidified air to the air compressor (10); heat energy generated by the air compressor (10) during operation is recovered and flows through the second air flow channel (50) to take away moisture adsorbed by the dehumidification wheel (60); in, A direct-cross heat exchanger (100) is also provided on the first air flow channel (40), and a cross flow channel is provided to the second air flow channel (50). The direct-cross heat exchanger (100) is provided between the dehumidification wheel (60) and the inlet (101) of the air compressor (10). The direct-cross heat exchanger (100) has two or more channels, wherein the inlet of one channel is connected to the outside air and the outlet is connected to the second air flow channel (50), and the inlet of the other channel is connected to the first air flow channel (40) and the outlet is connected to the inlet of the air compressor (10).

2. The air compressor inlet end dehumidification and energy saving system according to claim 1, wherein: The first air flow channel (40) and the second air flow channel (50) are arranged side by side in a shared partition wall (42).

3. The air compressor inlet end dehumidification and energy saving system according to claim 1, wherein: The two channels of the direct cross heat exchanger (100) are vertical but separated in layers.

4. The air compressor inlet end dehumidification and energy saving system according to claim 2, wherein: The two channels of the direct cross heat exchanger (100) are vertical but separated in layers.

5. According to the air compressor inlet end dehumidification and energy-saving system according to any one of claims 1 to 4, an air storage cylinder (20) is further provided downstream of the aftercooler (30) for storing compressed air.

6. The air compressor inlet end dehumidification and energy-saving system according to any one of claims 1 to 4 is further provided with a third air flow channel (e), the third air flow channel (e) being connected to the upstream and downstream of the first air flow channel (40) and serving as a bypass channel before startup, so that the air inhaled by the air compressor (10) when it is started is dry air.

7. The air compressor inlet end dehumidification and energy-saving system according to claim 5 is further provided with a third air flow channel (e), which is connected to the upstream and downstream of the first air flow channel (40) and serves as a bypass channel before startup, so that the air inhaled by the air compressor (10) when it is started is dry air.

8. The air compressor inlet end dehumidification and energy-saving system according to any one of claims 1 to 4, wherein: The air compressor (10) is a water-cooled air compressor, wherein a hot water heat exchanger (f) is provided in the second air flow channel (50), a cooling water heat exchanger (i) is provided in the first air flow channel (40), and a cooling water tower (h) is provided outside the first air flow channel (40) and the second air flow channel (50).

9. The air compressor inlet end dehumidification and energy-saving system according to claim 5, wherein: The air compressor (10) is a water-cooled air compressor, wherein a hot water heat exchanger (f) is provided in the second air flow channel (50), a cooling water heat exchanger (i) is provided in the first air flow channel (40), and a cooling water tower (h) is provided outside the first air flow channel (40) and the second air flow channel (50).

10. The air compressor inlet end dehumidification and energy-saving system according to claim 6, wherein: The air compressor (10) is a water-cooled air compressor, wherein a hot water heat exchanger (f) is provided in the second air flow channel (50), a cooling water heat exchanger (i) is provided in the first air flow channel (40), and a cooling water tower (h) is provided outside the first air flow channel (40) and the second air flow channel (50).

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