Dynamic compressor system and method of operation

Abstract

Dynamic compressor systems and methods of operation are provided herein. A compressor system includes a compressor and a variable flow extractor disposed downstream of the compressor to divide a compressor outlet flow into a recirculation flow and a system outlet flow. A variable flow injector is disposed upstream of the compressor, the variable flow injector mixing the recirculation flow with the system feed flow to form a compressor inlet flow. The controller is configured to receive first data indicative of a pressure of the system outlet flow, second data indicative of a flow rate of the system supply flow, and third data indicative of a flow rate of at least two of the system supply flow, the system outlet flow, and the recycle flow. The controller adjusts a flow rate of the recirculation flow via the variable flow extractor and the variable flow injector based on the first, second, and third data.

Description

Technical Field

[0001] These teachings generally concern compressors, and more specifically, systems and methods for adapting to flow turndown in compressors. Background Technology

[0002] Compressors may experience various operating conditions, such as wide ranges of inlet flow rates. In some cases, compressors may undergo large flow regulation, where the inlet flow rate drops below full load. Such large flow regulation can affect the overall performance of the compressor and may make it more difficult to maintain stable compressor operation. Therefore, a compressor system capable of adapting to flow regulation while maintaining the system outlet pressure within the target range may be desirable. Attached Figure Description

[0003] By providing the dynamic compressor system and operating method described in the following detailed description, especially when studied in conjunction with the accompanying drawings, various needs are at least partially met. A complete and feasible disclosure of all aspects of this description, including its best mode, is set forth in the specification with reference to the accompanying drawings, for those skilled in the art, wherein:

[0004] Figure 1 These are schematic diagrams of compressor systems according to various embodiments;

[0005] Figure 2 It is based on various embodiments of these teachings that communicate with the control unit. Figure 1 A schematic diagram of the compressor system;

[0006] Figure 3 This is a flowchart of a method for operating a compressor system according to various embodiments;

[0007] Figure 4 This is a flowchart of a method for operating a compressor system according to various embodiments;

[0008] Figure 5 Is as Figure 1 A graph showing the operating speed as a function of the compressor control ratio in a compressor system;

[0009] Figure 6 Is as Figure 1 A graph of the recirculation flow fraction as a function of the compressor control ratio in a compressor system;

[0010] Figure 7A Is as Figure 1 A graph of the flow coefficient as a function of the compressor control ratio in a compressor system; and

[0011] Figure 7B Is as Figure 1The graph shows the rise in stagnation pressure in the compressor system as a function of the compressor control ratio, caused by the mixing of recirculated flow and the rise in stagnation pressure throughout the system.

[0012] The elements in the accompanying drawings are shown for simplicity and clarity and are not necessarily drawn to scale. For example, the size and / or relative positioning of some elements in the drawings may be exaggerated relative to other elements to aid in understanding the various embodiments of this teaching. Furthermore, common but well-understood elements that are useful or necessary in commercially viable embodiments are generally not described to facilitate less obstructed observation of these different embodiments of this teaching. Certain actions and / or steps may be described or depicted in a specific sequence of occurrence, but those skilled in the art will understand that such specificity regarding the sequence is not actually necessary. Detailed Implementation

[0013] The dynamic compressor system and operating method described herein utilize a combination of variable features that can be actuated in real time to allow the compressor to respond to low inlet flow rates. The variable features of the dynamic compressor system include a variable flow extractor located downstream of the compressor to extract or split the flow from the compressor outlet into a recirculated flow and a system outlet flow. The recirculated flow recirculates a portion of the flow to maintain a flow rate sufficient for stable operation through the compressor, regardless of flow regulation at the system inlet. The dynamic compressor system also includes a variable flow injector located upstream of the compressor to inject or mix the recirculated flow into the compressor inlet. Additionally, in some aspects, the dynamic compressor system includes a variable area choke at the compressor outlet. Furthermore, in some aspects, the dynamic compressor system also includes variable inlet guide vanes at the compressor inlet. When the compressor system experiences changes in inlet flow rate, the variable flow extractor, variable flow injector, variable area choke, and / or variable inlet guide vanes can be actuated together to maintain the compressor system outlet pressure and / or flow rate within a target range.

[0014] Traditional methods for adapting to flow regulation involve reducing the compressor speed or implementing a small amount of recirculation from the compressor outlet to the compressor inlet to heat the compressor inlet supply, thereby allowing the compressor to operate reliably at lower flow rates. Using this traditional method to adapt to flow regulation results in a drop in the compressor's output pressure. Furthermore, high levels of flow regulation occurring over short periods can cause the compressor to stall.

[0015] Advantageously, the dynamic compressor system and operating method described herein can be used to adapt to flow regulation. That is, the dynamic compressor system can adjust its operating parameters in response to changes in the system input flow rate to maintain the system outlet pressure within a target range, particularly during high-level flow regulation. Furthermore, the dynamic compressor system can adjust its operating parameters to maintain the system outlet flow rate within a target range. Therefore, when the compressor undergoes high-level flow regulation, the dynamic compressor system and method described herein can maintain compressor operation and prevent stall or a significant drop in system outlet pressure.

[0016] The compressor system and operating methods described herein are envisioned for use in a variety of applications. One exemplary application is power-to-liquids (PTL) processing, which produces chemicals in liquid form at ambient temperature and pressure from renewable energy sources. PTL processing typically uses renewable energy (wind or solar) to generate hydrogen (H2) through water electrolysis. The hydrogen (H2) is then combined with carbon dioxide and used as a feedstock for the liquid synthesis reaction in the PTL process. Compressors can be used to maintain the feedstock to the liquid synthesis reactor at a target pressure. Recirculation compressors can also be used to recycle any unconverted feedstock gases, such as hydrogen (H2) and carbon dioxide, back to the liquid synthesis reactor to increase processing yield.

[0017] However, renewable energy sources can cause power input fluctuations in the PTL process, affecting the flow rate of hydrogen (H2) produced by electrolysis and leading to intermittent large-flow regulation of the hydrogen (H2) supply stream. Similarly, the recirculation compressor may also experience intermittent large-flow regulation of the recirculated gas stream. While batteries can be used to provide a constant power input to the PTL process and allow the compressor to operate at a single flow rate, they can add significant costs. By dynamically operating the compressor and the entire PTL process, the additional costs of storing intermittent renewable electricity can be avoided.

[0018] Many examples of PTL processes can be used. For instance, power-to-methanol (P2M) converts H2 from water electrolysis with carbon dioxide to produce methanol in a methanol synthesis reactor. Some versions of methanol synthesis require converting carbon dioxide into carbon monoxide, which can then combine with H2 to form a synthesis gas and be fed into the methanol synthesis reactor. For direct methanol synthesis, hydrogen and carbon dioxide can be used directly.

[0019] In another example, the PTL process may include a Fischer-Tropsch process, in which carbon dioxide is supplied and converted into carbon monoxide via a reverse water-gas shift or electrochemical reduction, and then combined with hydrogen to form a syngas. The syngas is then fed into a Fischer-Tropsch synthesis reactor to form liquid hydrocarbons.

[0020] In another example, PTL processing can include a direct carbon dioxide to hydrocarbon process, in which carbon dioxide and hydrogen are supplied and converted into liquid hydrocarbons in a single synthesis step.

[0021] Now turn to the attached image. Figure 1 A compressor system 100 is shown. The compressor system 100 can be operated to maintain the system outlet pressure over a wide range of flow rate regulation.

[0022] The compressor system 100 includes a compressor 102, a variable flow extractor 110 for separating and mixing recirculated flow, and a variable flow injector 122. In some embodiments, the compressor system 100 further includes a variable inlet guide vane 138 to ensure that fluid enters the compressor at a desired flow angle. In other embodiments, the compressor system 100 also includes a variable area damper 132 for adjusting the flow rate through the compressor 102.

[0023] Compressor 102 can be any suitable compressor, such as, but not limited to, a reciprocating compressor, a screw compressor, an axial or centrifugal turbo compressor. Compressor 102 includes a compressor inlet 102A and a compressor outlet 102B. Compressor inlet 102A is the portion of compressor 102 where the fluid to be compressed enters. Compressor inlet 102A is connected to compressor inlet path 106 and receives compressor inlet flow 106A. Compressor inlet flow 106A includes the fluid to be compressed. Compressor outlet 102B is the portion of compressor 102 where the compressed fluid exits. Compressor outlet 102B is connected to compressor outlet path 108. Compressor outlet 102B outputs compressor outlet flow 108A through compressor outlet path 108. Compressor outlet flow 108A includes compressed fluid. Compressor outlet 102B can deliver compressed fluid at a target pressure. In some configurations, the compressor inlet 102A is upstream of the impeller or rotor stage of the compressor 102, while the compressor outlet 102B is downstream of the impeller or rotor stage of the compressor 102.

[0024] A variable flow extractor 110 is disposed downstream of compressor 102. The variable flow extractor 110 is in fluid communication with compressor outlet 102B and receives at least a portion of compressor outlet flow 108A. The variable flow extractor 110 is coupled to and in fluid communication with recirculation path 112. The variable flow extractor 110 is also coupled to and in fluid communication with system outlet path 114. The variable flow extractor 110 splits compressor outlet flow 108A into recirculation flow 112A flowing through recirculation path 112 and system outlet flow 114A flowing through system outlet path 114. The variable flow extractor 110 is configured to split flow through the extractor into a first outlet flow 120A and a second outlet flow 121A radially outward from the first outlet flow 120A. Figure 1 In this configuration, the inner first outlet flow 120A is connected to the system outlet flow 114A, and the outer second outlet flow 121A is connected to the recirculation flow 112A. In other embodiments, the outer second outlet flow 121A may alternatively be connected to the system outlet flow 114A, and the inner first outlet flow 120A may be connected to the recirculation flow 112A. The flow split ratio between the first outlet flow 120A and the second outlet flow 121A is adjustable.

[0025] In some configurations, the variable flow extractor 110 includes an outer extractor body 116 within which an inner extractor body 118 is disposed. The outer extractor body 116 is hollow and, in some examples, is generally conical. In some examples, the inner extractor body 118 is also generally conical. At least a portion of the inner extractor body 118 is hollow to define a first outlet flow path 120 extending from the compressor outlet path 108 through the inner extractor body 118 to the system outlet path 114. A first outlet flow 120A flows through the first outlet flow path 120. The space between the inner extractor body 118 and the outer extractor body 116 defines a second outlet flow path 121, which is coupled to and in fluid communication with a recirculation path 112. A second outlet flow 121A flows through the second outlet flow path 121.

[0026] In some examples, the inner extractor body 118 may be translated upstream or downstream within the outer extractor body 116. Translating the inner extractor body 118 upstream or downstream within the outer extractor body 116 adjusts the split ratio of the first outlet flow 120A to the second outlet flow 121A. For example, translating the inner extractor body 118 upstream restricts the area of ​​the second outlet flow path 121, resulting in less flow in the second outlet flow 121A (e.g., less compressor outlet flow 108A flowing towards the recirculation path 112) and more flow in the first outlet flow 120A. Translating the inner extractor body 118 downstream expands the area of ​​the second outlet flow path 121, resulting in more flow in the second outlet flow 121A (e.g., more compressor outlet flow 108A flowing towards the recirculation path 112) and less flow in the first outlet flow 120A.

[0027] It should be understood that the configuration of the variable flow extractor 110 is one example of how the variable flow extractor 110 can be configured to split the compressor outlet flow 108A, and the variable flow extractor 110 can have any suitable configuration to change the amount of flow through each of the recirculation path 112 and the system outlet path 114. For example, in some embodiments, the variable flow extractor 110 may include a central manifold that opens and closes to control the split ratio, similar to the variable area orifice 130 described herein with reference to the variable flow injector 122.

[0028] A variable flow injector 122 is disposed upstream of compressor 102. A variable flow extractor 110 is coupled to and in fluid communication with system supply path 128. Variable flow injector 122 receives system supply flow 128A from system supply path 128. Variable flow injector 122 is also coupled to and in fluid communication with recirculation path 112. Variable flow injector 122 receives at least a portion of recirculation flow 112A from recirculation path 112. Variable flow injector 122 is in fluid communication with compressor inlet 102A and outputs at least a portion of compressor inlet flow 106A. Variable flow injector 122 is configured to mix a flow from second inlet flow 125A with a flow from a first inlet flow 123A radially inward of second inlet flow 125A. For example, variable flow injector 122 may be configured to mix recirculation flow 112A with system supply flow 128A to output injector outlet flow 103. Figure 1In this embodiment, the inner first inlet flow 123A is connected to the system supply flow 128A, while the second inlet flow 125A is connected to the recirculation flow 112A. In other embodiments, the outer second inlet flow 125A may alternatively be connected to the system supply flow 128A, and the inner first inlet flow 123A may be connected to the recirculation flow 112A. Additionally, in some embodiments, the inner injector body 126 may include an opening to allow a portion of the second inlet flow 125A to premix with the first inlet flow 123A within the first inlet flow path 123 before the flow reaches the variable area orifice 130. The variable flow injector 122 may have a variable nozzle geometry that allows adjustment of the mixing ratio of the second inlet flow 125A into the first inlet flow 123A.

[0029] In some configurations, the variable flow injector 122 includes an outer injector body 124, within which an inner injector body 126 is disposed. The outer injector body 124 is hollow and, in some examples, includes a tapered portion. In some examples, the inner injector body 126 also includes a tapered portion. At least a portion of the inner injector body 126 is hollow to define a first inlet flow path 123 extending from the system supply path 128 through the inner injector body 126 to the compressor inlet path 106. A first inlet flow 123A flows through the first inlet flow path 123. The space between the outer injector body 124 and the inner injector body 126 defines a second inlet flow path 125, which is coupled to and in fluid communication with the recirculation path 112. A second inlet flow 125A flows through the second inlet flow path 125.

[0030] In some examples, the internal injector body 126 has a variable area orifice 130. Changing the area of ​​the variable area orifice 130 adjusts the mixing ratio of the second inlet flow 125A into the first inlet flow 123A. For example, reducing the area of ​​the variable area orifice 130 restricts the outlet of the first inlet flow path 123 and increases the area of ​​the second inlet flow path 125, resulting in more flow from the second inlet flow 125A into the compressor inlet flow 106A (e.g., more flow from the recirculation path 112 to the compressor inlet flow 106A) and less flow from the first inlet flow 123A into the compressor inlet flow 106A. This increases the mixing ratio. Increasing the area of ​​the variable area orifice 130 expands the outlet of the first inlet flow path 123 and reduces the area of ​​the second inlet flow path 125, resulting in less flow from the second inlet flow 125A into the compressor inlet flow 106A (e.g., less flow from the recirculation path 112 to the compressor inlet flow 106A) and more flow from the first inlet flow 123A into the compressor inlet flow 106A. This reduces the mixing ratio.

[0031] It should be understood that the configuration of the variable flow injector 122 is an example of a variable geometry and an example of how the variable flow injector 122 can be configured to mix the system supply flow 128A and the recirculation flow 112A, and the variable flow injector 122 can have any suitable configuration to vary the amount of flow mixed from the recirculation flow 112A into the compressor inlet flow 106A. For example, in some embodiments, the variable flow injector 122 may include a translationally movable inner body that slides to control the mixing ratio, similar to the inner extractor body 118 described herein with reference to the variable flow extractor 110.

[0032] In some embodiments, the compressor system 100 further includes a variable area damper 132. The variable area damper 132 is disposed in the compressor outlet path 108. The variable area damper 132 is positioned downstream of the compressor 102 and upstream of the variable flow extractor 110. The variable area damper 132 is coupled to and in fluid communication with the variable flow extractor 110. The variable area damper 132 is also coupled to and in fluid communication with the compressor outlet 102B. In some configurations, the variable area damper 132 and the variable flow extractor 110 are a single mechanically integrated device.

[0033] In some configurations, the variable area damper 132 includes an orifice 136 that is adjustable to modify the flow area of ​​the variable area damper 132. Adjusting or modifying the flow area of ​​the variable area damper 132 can adjust the flow coefficient of the compressor 102. At low flow coefficients, the compressor 102 may approach stall. At high flow coefficients, for example, the compressor 102 may reach its limits, and the amount of flow that can pass through may be restricted, resulting in decreased efficiency. Adjusting the orifice to control the flow area of ​​the variable area damper 132 can set the flow coefficient of the compressor 102 within a desired range. In some embodiments, the variable area damper 132 and the variable inlet guide vane 138 are a single mechanically integrated device. In some embodiments, the variable inlet guide vane 138 can functionally serve as the variable area damper 132. In some embodiments, the variable area damper 132 may be implemented in the shape of a variable outlet guide vane.

[0034] In some embodiments, the compressor system 100 further includes a variable inlet guide vane 138. The variable inlet guide vane 138 is disposed on the compressor inlet path 106. The variable inlet guide vane 138 is positioned upstream of the compressor 102 and downstream of the variable flow injector 122. The variable inlet guide vane 138 is coupled to and in fluid communication with the variable flow injector 122. The variable inlet guide vane 138 is coupled to and in fluid communication with the compressor inlet 102A. The variable inlet guide vane 138 ensures that incoming fluid enters the compressor inlet 102A at a desired flow angle. The variable inlet guide vane 138 includes at least one guide vane 140. At least one guide vane 140 is variable pitch and has a pitch or angle 142 that can be adjusted based on changes in the flow rate through the compressor 102. Adjusting the pitch or angle 142 can adjust the swirl of the compressor inlet flow 106A in a manner that improves the efficiency of the compressor 102.

[0035] In some embodiments, the recirculation path 112 includes a flow control valve 113. The flow control valve 113 is configured to control the flow rate of the recirculation flow 112A.

[0036] Figure 2 Various components of a compressor system 100 operatively communicating with a controller 150 according to some embodiments are shown. For example, the controller 150 may operatively communicate with one or more of the compressor 102, variable flow extractor 110, variable flow injector 122, variable inlet guide vane 138, or variable area damper 132. The controller 150 may be configured to actuate one or more of the components of the compressor system 100. The controller 150 may be configured to perform various operations of the compressor system.

[0037] The controller 150 typically includes one or more processors 158 and / or a microprocessor. The memory 152 stores operating code or a set of instructions 156 executed by the controller 150 and / or one or more processors 158 to implement the functions of the compressor system 100 or a portion thereof. In some embodiments, the memory 152 may also store some or all of the data 154 associated with the operation of the compressor system 100.

[0038] Controller 150 may be implemented as one or more processors 158. Similarly, memory 152 may be implemented as one or more memory devices (such as one or more processor-readable and / or computer-readable media) and may include volatile and / or non-volatile media (such as RAM, ROM, EEPROM, flash memory, and / or other memory technologies). Furthermore, memory 152 is shown as being internal to controller 150; however, memory 152 may be internal memory, external memory, or a combination of internal and external memory. Additionally, controller 150 typically includes a power supply (not shown), which may be rechargeable and / or able to receive power from an external source.

[0039] User interface 162 can be used to control one or more components of compressor system 100. User interface 162 can be used for user input and / or output display. For example, user interface 162 may include any known input / output (I / O) device 160, such as one or more buttons, knobs, selectors, switches, keys, touch input surfaces, audio inputs, and / or displays. In addition, user interface 162 may include one or more output display devices (such as lights, visual indicators, displays, etc.) to convey information to the user (such as, but not limited to, communication information, status information, order information, delivery information, notifications, errors, conditions, and / or other such information). Similarly, in some embodiments, user interface 162 may include an audio system that can receive audio commands or requests verbally issued by the user and / or output audio content, alarms, etc.

[0040] The controller 150 also communicates with one or more sensors 167 in the engine. Sensors 167 may be located at one or more flow paths or engine components to measure engine data, such as pressure and / or flow rate in the flow paths, or the speed (e.g., rpm) of rotating components (such as compressor 102). For example, pressure or flow sensors may be located at recirculation path 112, system supply path 128, injector outlet flow 103, compressor inlet path 106, compressor outlet path 108, system outlet path 114, and / or between variable area damper 132 and variable flow extractor 110. In some embodiments, pressure or flow sensors may be located within variable flow injector 122, compressor 102, variable area damper 132, and / or variable flow extractor 110. The number and location of sensors in the engine may vary. In some embodiments, flow or pressure data for one or more flow paths may be measured directly by sensors or estimated based on operating parameters at sensors and / or other locations in the engine.

[0041] One or more components of the compressor system 100, particularly the compressor 102, the variable flow extractor 110, the variable flow injector 122, the variable area damper 132 or the variable inlet guide vane 138, and the controller 150, communicate with each other via a network 164. The network 164 can be any suitable communication network, such as a LAN, WAN, the Internet, cellular, Wi-Fi, and other such communication networks, or a combination of two or more such networks.

[0042] In operation, controller 150 is configured to actuate one or more of compressor 102, variable flow extractor 110, variable flow injector 122, variable area damper 132, or variable inlet guide vane 138. For example, controller 150 may be configured to actuate one or more of variable flow extractor 110, variable flow injector 122, variable area damper 132, or variable inlet guide vane 138 to maintain the pressure of system outlet flow 114A at a target pressure. Controller 150 may also be configured to actuate one or more of variable flow extractor 110, variable flow injector 122, variable area damper 132, or variable inlet guide vane 138 to maintain the flow rate of system outlet flow 114A at a target flow rate. In some embodiments, controller 150 may be configured to control the rotational speed of compressor 102 to maintain the flow rate of system outlet flow 114A at the target flow rate. By operating these variable components to maintain the target flow rate and / or target pressure of the system outlet flow 114A, the compressor 102 is able to adapt to a wider range of flow regulation without sacrificing output flow and / or pressure, compared to conventional methods such as individually changing the speed of the compressor 102.

[0043] In some embodiments, controller 150 may control compressor 102, recirculation path 112, variable flow injector 122, system supply path 128, and / or variable area damper 132 based on a feedback loop, using data captured and / or estimated from one or more sensors 167 in the engine. For example, controller 150 may gradually change the operating parameters of engine components until a measured parameter indicating pressure or flow rate at a specific location is reached.

[0044] Figure 3 A method 170 for operating a compressor system 100 according to some embodiments is shown. In some methods, a controller 150 is configured to perform method 170 or a portion thereof.

[0045] At box 172, controller 150 receives initial data indicating the pressure of system outlet flow 114A. As used herein, the data indicating pressure or flow rate can be measured directly by a flow rate / pressure sensor (such as sensor 167) or derived from other measurements sufficiently related to the flow rate or pressure at the flow point.

[0046] At block 174, controller 150 receives second data indicating the pressure of system supply flow 128A. At block 174, controller 150 also receives third data indicating the flow rate of recirculation flow 112A and the flow rate of at least one of system supply flow 128A and system outlet flow 114A. In some embodiments, the flow rates of system supply flow 128A and / or system outlet flow 114A are direct flow rate measurements using a flow rate sensor, such as a venturi. In other embodiments, the flow rate is derived by measuring quantities indicating the flow rate, such as total and static pressure at a particular location, or pressure ratio, and work input on the compressor. In one example, the flow rates of system supply flow 128A and / or system outlet flow 114A are estimated based on measured pressures at injector outlet flow 103 and guide vane 140, and the rpm of compressor 102.

[0047] At block 176, controller 150 adjusts the flow rate of recirculation flow 112A via variable flow extractor 110 and / or variable flow injector 122 based on first, second, and third data. In some examples, the controller adjusts the flow rate of recirculation flow 112A to maintain the pressure of system outlet flow 114A within a target range. In some examples, the controller adjusts the flow rate of recirculation flow 112A to maintain the flow rate of system outlet flow 114A within a target range. In some embodiments, controller 150 may alternatively or additionally adjust the compressor speed (i.e., revolutions per minute (RPM)) based on the first, second, and third data to maintain the flow rate of system outlet flow 114A within a target range. In some embodiments, the compressor RPM may be adjusted in coordination with the adjustment of the recirculation flow rate.

[0048] In some methods, controller 150 adjusts the split ratio of variable flow extractor 110 to adjust the flow rate of recirculated flow 112A. For example, controller 150 may actuate the inner extractor body 118 of variable flow extractor 110 to move the inner extractor body 118 upstream or downstream, thereby adjusting the split ratio.

[0049] In some methods, controller 150 adjusts the mixing ratio of variable flow injector 122 to adjust the flow rate of recirculated flow 112A. For example, controller 150 may actuate the variable area orifice 130 of variable flow injector 122 to increase or decrease the flow area of ​​variable flow injector 122, thereby adjusting the mixing ratio. In some embodiments, the adjustment in block 176 can be made based on a feedback loop using measurement data from sensor 167.

[0050] At box 178, controller 150 adjusts variable area damper 132 based on first, second, and third data. In some examples, the controller adjusts variable area damper 132 to maintain the pressure of system outlet flow 114A within a target range. In some examples, the controller adjusts variable area damper 132 to maintain the flow rate of system outlet flow 114A within a target range.

[0051] In some methods, controller 150 adjusts the orifice 136 of the variable area damper 132 based on first, second, and third data. In some methods, controller 150 adjusts the orifice 136 of the variable area damper 132 based on first, second, and third data to achieve a target flow coefficient for the compressor. In some embodiments, the adjustment in block 178 can be made using measurement data from sensor 167 based on a feedback loop.

[0052] At block 180, controller 150 adjusts variable inlet guide vane 138 based on first, second, and third data. In some examples, the controller adjusts variable inlet guide vane 138 to maintain the pressure of system outlet flow 114A within a target range. In some examples, the controller adjusts variable inlet guide vane 138 to maintain the flow rate of system outlet flow 114A within a target range. In some embodiments, the adjustment in block 180 can be made based on a feedback loop using measurement data from sensor 167.

[0053] In some methods, controller 150 adjusts the pitch or angle 142 of at least one guide vane 140 of variable inlet guide vane 138 based on first, second, and third data measured and / or estimated by sensors. Controller 150 can automatically adjust the pitch or angle 142 of at least one guide vane 140 based on sensor data to maintain the pressure and / or flow rate of system outlet flow 114A within a target range.

[0054] In some embodiments, the controller 150 also operatively communicates with the flow control valve 113. The controller 150 may actuate the flow control valve 113 based on first, second, and third data to maintain the pressure and / or flow rate of the system outlet flow 114A within a target range. The controller 150 may actuate the flow control valve 113 to adjust the flow rate of the recirculation flow 112A.

[0055] In some embodiments, reference Figure 4 The adjustments to the various engine components described can be made via a feedback loop using data measured by sensor 167.

[0056] Figure 4 A method 182 is illustrated for operating a compressor system including a compressor according to some embodiments. The compressor receives a system supply flow and outputs a system outlet flow. In some methods, the compressor system is compressor system 100 or a portion thereof, and a controller 150 is configured to perform method 182 or a portion thereof.

[0057] At box 184, method 182 includes splitting the compressor outlet flow into a recirculation flow and a system outlet flow via a variable flow extractor. In some examples, the variable flow extractor is a reference... Figure 1 The variable flow extractor 110 is shown and described.

[0058] At block 186, method 182 includes mixing the recirculated flow into the system supply flow via a variable flow injector to form the compressor inlet flow. In some examples, the variable flow injector is a reference... Figure 1 The variable flow injector 122 is shown and described.

[0059] At box 187, method 182 includes receiving first data including the pressure of the system outlet flow.

[0060] At block 188, method 182 includes receiving second data including the pressure of the system supply flow. Controller 150 also receives third data including the flow rate of recirculation flow 112A and the flow rate of at least one of system supply flow 128A and system outlet flow 114A.

[0061] At block 190, method 182 includes adjusting the flow rate of the recirculation flow via a variable flow extractor and a variable flow injector based on first, second, and third data. In some methods, the flow rate of the recirculation flow is adjusted to maintain the pressure of the system outlet flow at or within a target pressure range. In some methods, the flow rate of the recirculation flow is adjusted to maintain the flow rate of the system outlet flow at a given flow rate or within a target flow rate range. In some embodiments, controller 150 may alternatively or additionally adjust the compressor RPM based on the first, second, and third data. In some embodiments, the compressor RPM may be adjusted in coordination with the adjustment of the recirculation flow rate. In some embodiments, the adjustment in block 190 may be performed based on a feedback loop using measurement data from sensor 167.

[0062] In some embodiments, method 182 further includes adjusting the flow rate of the compressor outlet flow via a variable area damper disposed upstream of the variable flow extractor. In some examples, the variable area damper is a reference... Figure 1 A variable area damper 132 is shown and described. The variable area damper may include an orifice that is adjustable to modify the flow area of ​​the damper. When the variable area damper is constructed in this manner, the orifice size can be adjusted based on first, second, and third data to maintain the target flow coefficient of the compressor.

[0063] In some embodiments, method 182 further includes adjusting the flow rate of the compressor inlet flow via a variable inlet guide vane. The variable inlet guide vane is positioned upstream of the compressor and downstream of the variable flow injector. In some examples, the variable inlet guide vane is a reference vane. Figure 1 A variable inlet guide vane 138 is shown and described. In some methods, the variable inlet guide vane includes at least one vane with an adjustable angle. When the variable inlet guide vane is constructed in this manner, the angle of at least one vane can be adjusted based on first, second, and third data.

[0064] In some embodiments, method 182 may alternatively or additionally adjust the compressor RPM based on the first, second, and third data. That is, the system may adjust the flow recirculation rate, the compressor RPM, or both based on the first, second, and third data.

[0065] In other embodiments, method 182 further includes adjusting the flow rate of the recirculation flow via a flow control valve disposed in the recirculation flow. In some examples, the flow control valve is a reference valve. Figure 1 The flow control valve 113 is shown and described. For example, the flow control valve can be controlled at least in part based on first, second, and third data to maintain the pressure and / or flow rate of the system outlet flow within a target range.

[0066] In some embodiments, reference Figure 4 The adjustments to the various engine components described can be made via a feedback loop using data measured by sensor 167. Figure 5 , Figure 6 , Figure 7A and Figure 7BThese are graphs illustrating example relationships between parameters of a dynamic compressor according to some embodiments of the compressor system 100 described herein. These graphs are provided for illustrative purposes only to show the relationships between compressor parameters in some embodiments. The values ​​and scales in these graphs may not correspond to actual values ​​and scales. In some graphs, values ​​and scales are not included because they can vary based on the specific implementation, construction, and operating conditions. In these graphs, the control ratio refers to the range within which the compressor can operate effectively. Specifically, it is the ratio of the maximum flow rate to the minimum flow rate at which the compressor can maintain stable operation. A control ratio of 1 typically corresponds to the compressor's design flow rate.

[0067] exist Figure 5 In the graph 196 shown, the x-axis represents the regulation ratio of the flow rate through compressor 102, and the y-axis represents the ratio of the operating speed of compressor 102 to its design speed. When the regulation ratio is approximately 1, compressor 102 operates at approximately its design speed on the Y-axis.

[0068] exist Figure 6 In the graph 198 shown, the x-axis represents the regulation ratio of the flow through compressor 102, and the y-axis represents the flow fraction recirculated from the outlet of compressor 102 to the inlet of compressor 106. When the regulation ratio is approximately 1, no flow is recirculated. However, when the regulation ratio drops below a predetermined threshold (t), recirculation is required. As the regulation ratio decreases further from the threshold, the increasing flow is recirculated through compressor 102 via recirculation flow 112A. The threshold can be set differently depending on the engine construction and / or operating conditions.

[0069] As shown in graphs 196 and 198, when the flow rate is shifted to a lower level, as indicated by a lower control ratio, the flow rate in recirculation stream 112A increases, and the speed of compressor 102 decreases to meet the target pressure. At higher flow rates, as indicated by a higher control ratio, recirculation in recirculation stream 112A is not required.

[0070] exist Figure 7AIn the graph 200 shown, the x-axis represents the flow rate regulation ratio through compressor 102, and the y-axis represents the flow coefficient of compressor 102. The flow coefficient (FlowCoeft) is defined as %FlowCoeft = (Mass Flow through Compressor at 106) / (Density at system feedpath 128 * (pi * Rtip^2) * (2 * pi * N_rpm / 60 * Rtip))). Here, Rtip is the tip radius of the upstream compressor rotor, and N_rpm is the number of revolutions per minute of the compressor shaft.

[0071] exist Figure 7B In the graph 202 shown, the x-axis represents the flow rate regulation ratio through compressor 102, and the y-axis represents the compressor-to-system pressure ratio, which is the total stagnation pressure rise from system supply path 128 to compressor inlet path 106 caused by the mixing of recirculated flow on the stagnation total pressure rise from system supply path 128 to system outlet path 114. Typically, stagnation pressure refers to the static pressure when a moving mass of fluid isentropically stationary.

[0072] As shown in graphs 200 and 202, for a wide range of control ratios (e.g., from about 0.6 to about 1.2), the flow coefficient of compressor 102 remains higher than the minimum flow coefficient value representing the compressor before stall. Furthermore, because mixing the recirculated fluid helps to increase the pressure, the target pressure can be reached at low speeds.

[0073] It should be understood that the terms "upstream" and "downstream" refer to the relative directions of fluid flow within a fluid path. For example, "upstream" refers to the direction from which the fluid flows, and "downstream" refers to the direction from which the fluid flows.

[0074] Unless otherwise specified herein, the terms and expressions used herein have the ordinary technical meanings that those skilled in the art would assign to them. Unless otherwise specifically indicated, the word "or" as used herein should be interpreted as having a disjunctive structure rather than a conjunctive structure. Unless otherwise stated herein, the terms "connection," "fixed," "attached," etc., refer both to direct connection, fixation, or attachment, and to indirect connection, fixation, or attachment via one or more intermediate components or features.

[0075] Unless the context clearly indicates otherwise, the singular forms “a,” “a,” and “the” include plural references.

[0076] As used herein throughout the specification and claims, approximate language is applied to modify any quantitative expression that may allow for variation without altering its underlying function. Therefore, values ​​modified by terms such as “about,” “approximate,” and “substantially” are not limited to specified exact values. In at least some cases, approximate language may correspond to the precision of the instrument used to measure the value, or the precision of the method or machine used to construct or manufacture the part and / or system. For example, approximate language may refer to a margin of 10%.

[0077] Further aspects of this disclosure are provided by the subject matter of the following clauses:

[0078] A compressor system includes: a compressor having a compressor inlet receiving a compressor inlet flow and a compressor outlet outputting a compressor outlet flow; a variable flow extractor disposed downstream of the compressor to split the compressor outlet flow into a recirculation flow and a system outlet flow; a variable flow injector disposed upstream of the compressor, the variable flow injector receiving a system supply flow and mixing the recirculation flow with the system supply flow to form the compressor inlet flow; and a controller operatively coupled to the variable flow extractor and the variable flow injector, the controller being configured to: receive first data indicating the pressure of the system outlet flow; receive second data indicating the pressure of the system supply flow; receive third data indicating the flow rate of the recirculation flow and the flow rate of at least one of the system supply flow and the system outlet flow; and adjust the flow rate of the recirculation flow via the variable flow extractor and the variable flow injector based on the first data, the second data, and the third data to maintain the pressure of the system outlet flow within a target range.

[0079] In any of the preceding clauses, the compressor system wherein the controller is further configured to collaboratively adjust the flow rate of the recirculation flow and the rotational speed of the compressor based on the first data, the second data, and the third data.

[0080] In any of the preceding clauses, the compressor system wherein the variable flow extractor is configured to split the flow into a first outlet flow and a second outlet flow, the splitting ratio of the first outlet flow to the second outlet flow being adjustable.

[0081] In any of the preceding clauses, the compressor system wherein the controller is configured to adjust the flow rate of the recirculated flow by adjusting the split ratio of the variable flow extractor.

[0082] In any of the preceding clauses, the compressor system wherein the variable flow injector is configured to mix streams from a first inlet stream and a second inlet stream, the mixing ratio of the second inlet stream to the first inlet stream being adjustable.

[0083] In any of the preceding clauses, the compressor system wherein the controller is configured to adjust the flow rate of the recirculated flow by adjusting the mixing ratio.

[0084] The compressor system according to any of the foregoing clauses further includes: a variable area damper disposed between the compressor outlet and the variable flow extractor, and in fluid communication with the compressor outlet and the variable flow extractor.

[0085] In any of the preceding clauses, the compressor system wherein the variable area damper and the variable flow extractor are a single mechanically integrated device.

[0086] The compressor system according to any of the foregoing clauses, wherein the variable area damper includes an orifice adjustable to modify the flow area, and wherein the controller is further configured to adjust the orifice based on the first data, the second data, and the third data to achieve the target flow coefficient of the compressor.

[0087] The compressor system according to any of the foregoing clauses further includes: a variable inlet guide vane disposed between the compressor inlet and the variable flow injector, and in fluid communication with the compressor inlet and the variable flow injector.

[0088] In any of the preceding clauses, the compressor system wherein the variable inlet guide vane and the variable flow injector are a single mechanically integrated unit.

[0089] In any of the preceding clauses, the compressor system includes at least one blade having an adjustable angle, and the controller is further configured to adjust the angle of the at least one blade.

[0090] The compressor system according to any of the foregoing clauses further includes: a recirculation path that receives the recirculated flow from the variable flow extractor and supplies the recirculated flow to the variable flow injector; and a flow control valve disposed in the recirculation path to control the flow rate of the recirculated flow.

[0091] A method of operating a compressor system including a compressor, the compressor system receiving a system supply stream and outputting a system outlet stream, the method comprising: splitting the compressor outlet stream into a recirculation stream and the system outlet stream via a variable flow extractor; mixing the recirculation stream into the system supply stream via a variable flow injector to output an inlet stream of the compressor; receiving first data indicating the pressure of the system outlet stream; receiving second data indicating the pressure of the system supply stream; receiving third data indicating the flow rate of the recirculation stream and the flow rate of at least one of the system supply stream and the system outlet stream; and adjusting the flow rate of the recirculation stream and the rotational speed of the compressor via the variable flow extractor and the variable flow injector based on the first data, the second data, and the third data to maintain the pressure of the system outlet stream at a target pressure.

[0092] The method according to any of the foregoing clauses further includes: adjusting the flow rate of the outlet flow of the compressor via a variable area damper upstream of the variable flow extractor.

[0093] According to any of the foregoing provisions, the variable area damper includes an orifice that can be adjusted to modify the flow area, and the method further includes adjusting the size of the orifice based on the second data to achieve the target flow coefficient of the compressor.

[0094] The method according to any of the foregoing clauses further includes: adjusting the flow rate of the inlet flow of the compressor via a variable inlet guide vane downstream of the variable flow injector.

[0095] According to any of the foregoing clauses, the variable inlet guide vane includes at least one vane having an adjustable angle, and the method further includes adjusting the angle of the at least one vane.

[0096] The method according to any of the foregoing clauses further includes: adjusting the flow rate of the recirculation flow via a flow control valve disposed in the recirculation flow.

[0097] A compressor system includes: a compressor having a compressor inlet receiving a compressor inlet flow and a compressor outlet outputting a compressor outlet flow; a variable flow extractor disposed downstream of the compressor to split the compressor outlet flow into a recirculation flow and a system outlet flow; a variable flow injector disposed upstream of the compressor, receiving a system supply flow and mixing the recirculation flow with the system supply flow to form the compressor inlet flow; a variable area damper disposed between the compressor outlet and the variable flow extractor, and in fluid communication with both the compressor outlet and the variable flow extractor; and a variable inlet guide vane disposed between the compressor inlet and the system outlet flow. A variable flow injector is fluidly connected to and from the compressor inlet and the variable flow injector; and a controller operatively coupled to the variable flow extractor, the variable flow injector, the variable area damper, and the variable inlet guide vane, the controller being configured to: receive first data indicating the pressure of the system outlet flow; receive second data indicating the pressure of the system supply flow; receive third data indicating the flow rate of the recirculation flow and the flow rate of at least one of the system supply flow and the system outlet flow; and actuate the variable flow extractor, the variable flow injector, the variable area damper, and the variable inlet guide vane based on the first data, the second data, and the third data to maintain the pressure of the system outlet flow within a target range.

Claims

1. A compressor system characterized by, Comprising: a compressor having a compressor inlet that receives a compressor inlet flow and a compressor outlet that outputs a compressor outlet flow; a variable flow extractor disposed downstream of the compressor to split the compressor outlet flow into a recirculation flow and a system outlet flow; a variable flow injector disposed upstream of the compressor that receives a system supply flow and mixes the recirculation flow with the system supply flow to form the compressor inlet flow; and a controller operably coupled to the variable flow extractor and the variable flow injector, the controller configured to: receive first data indicative of a pressure of the system outlet flow; receive second data indicative of a pressure of the system supply flow; receive third data indicative of a flow rate of the recirculation flow and a flow rate of at least one of the system supply flow and the system outlet flow; and adjust, based on the first data, the second data, and the third data, a flow rate of the recirculation flow via the variable flow extractor and the variable flow injector to maintain the pressure of the system outlet flow within a target range. wherein, 2. The compressor system of claim 1, wherein, the controller is further configured to adjust, based on the first data, the second data, and the third data, the flow rate of the recirculation flow and a rotational speed of the compressor in coordination. wherein, 3. The compressor system of claim 1, wherein, the variable flow extractor is configured to split flow into a first outlet flow and a second outlet flow, a split ratio of the first outlet flow to the second outlet flow being adjustable. wherein, 4. The compressor system of claim 3, wherein, the controller is configured to adjust the flow rate of the recirculation flow by adjusting the split ratio of the variable flow extractor. wherein, 5. The compressor system of claim 1, wherein, the variable flow injector is configured to mix flow from a first inlet flow and a second inlet flow, a mix ratio of the second inlet flow to the first inlet flow being adjustable. wherein, 6. The compressor system of claim 5, wherein, the controller is configured to adjust the flow rate of the recirculation flow by adjusting the mix ratio. further comprising:

7. The compressor system of claim 1, wherein, a variable area blocker door disposed between and in fluid communication with the compressor outlet and the variable flow extractor. wherein, 8. The compressor system of claim 7, wherein, the variable area blocker door and the variable flow extractor are a single mechanical integrated device. wherein, 9. The compressor system of claim 7, wherein, the variable area blocker door includes an orifice adjustable to modify a flow area, and wherein the controller is further configured to adjust the orifice, based on the first data, the second data, and the third data, to achieve a target flow coefficient of the compressor. further comprising:

10. The compressor system of claim 1, wherein, a variable inlet guide vane disposed between and in fluid communication with the compressor inlet and the variable flow injector. ​

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