Multi-stage compression gas condensate liquid coordinated discharge system and gas compression equipment

Abstract

The disclosure provides a multi-stage compression gas condensate cooperative discharge system and a gas compression device. The cooperative discharge system comprises, in sequence along a gas flow direction, a gas inlet assembly, a primary compression host, an intermediate cooler, an intermediate gas-liquid separator, a secondary compression host, a post-stage cooler, and a final-stage gas-liquid separator. At least one of the intermediate gas-liquid separator and the final-stage gas-liquid separator comprises a shell, a gas guide pipe arranged in the shell, and a liquid separation plate arranged below the gas guide pipe. A liquid level detection assembly is arranged in a liquid collection space. The liquid level detection assembly comprises a reference detection part and a liquid level measurement part. A controller is configured to compensate a liquid level measurement signal based on a reference signal to determine a real-time liquid level, and to control a controllable liquid discharge valve to open when the real-time liquid level reaches a liquid discharge starting liquid level. The above technical solution can reduce condensate residue and avoid excessive liquid discharge from damaging the liquid seal and causing compression gas leakage.

Description

Technical Field

[0001] The present invention relates to the field of gas compression equipment technology, and in particular to a multi-stage compressed gas condensate co-discharge system and a gas compression device. Background Technology

[0002] In the semiconductor industry, pneumatic pumps, pneumatic valves, and other components are commonly used. These valves primarily use compressed air as their driving force, making compressed air the main power source for production equipment. Compressed air is mainly generated by air compressors (generally screw or centrifugal types). Air compressors compress atmospheric air to provide compressed air at the required pressure.

[0003] In the process of producing compressed air, the gas is compressed in stages to achieve the pressure required at the end of the production process. During compression, the gas undergoes rapid changes in temperature and pressure, causing water to be released from the air. This moisture is then discharged to the outside.

[0004] In practical applications, drainage operations are performed at a fixed frequency. During the drainage process, compressed air also escapes, wasting a significant amount of compressed air. Summary of the Invention

[0005] In view of this, embodiments of the present invention provide a multi-stage compressed gas condensate co-discharge system and a gas compression device, which can reduce condensate residue and avoid excessive discharge that could damage the liquid seal and cause compressed gas leakage.

[0006] In a first aspect, embodiments of this disclosure provide a multi-stage compressed gas condensate co-discharge system, comprising: an intake assembly, a primary compressor, an intercooler, an intermediate gas-liquid separator, a secondary compressor, a post-cooler, and a final gas-liquid separator connected sequentially along the gas flow direction; At least one of the intermediate gas-liquid separator and the final gas-liquid separator includes a housing, a gas guide pipe disposed within the housing, and a liquid separator plate disposed below the gas guide pipe, with a liquid collection space formed below the liquid separator plate; the housing is provided with a gas-liquid inlet and a gas phase outlet, the gas guide pipe is used to guide the gas-liquid mixture passing through the gas-liquid inlet to the liquid separator plate, and the gas phase outlet communicates with the gas phase space of the housing located above the liquid separator plate; the liquid collection space is connected to a drain channel, and the drain channel is provided with a controllable drain valve; The liquid collection space is equipped with a liquid level detection component, which includes a reference detection unit and a liquid level measurement unit. The reference detection unit is located below the target liquid seal level and is used to output a reference signal characterizing the equivalent dielectric parameter of the condensate. The liquid level measurement unit is used to output a liquid level measurement signal characterizing the liquid level of the condensate in the annular liquid collection space. The controller is configured to compensate the liquid level measurement signal according to the reference signal to determine the real-time liquid level, control the controllable drain valve to open when the real-time liquid level reaches the drain start liquid level, determine the liquid level drop rate according to the real-time liquid level continuously acquired during the draining period, determine the dynamic early closing timing according to the liquid level drop rate and the closing response parameters of the controllable drain valve, and output a closing command to the controllable drain valve.

[0007] Optionally, the liquid level detection assembly includes a reference electrode and a measuring electrode spaced apart along the axial direction of the housing, with the measuring electrode located above the reference electrode. The reference electrode constitutes the reference detection unit, and the plurality of measuring electrodes constitute the liquid level measuring unit. The reference electrode and the measuring electrode, together with the common electrode, form a capacitance detection circuit, and the common electrode is the housing; the reference electrode is located below the target liquid seal level, and the measuring electrodes are distributed sequentially along the direction from the target liquid seal level toward the drain start level.

[0008] Optionally, the controller pre-stores a reference reference signal corresponding to the reference detection unit, a measurement reference signal corresponding to the liquid level measurement unit, and a preset correspondence between the compensation liquid level feature value and the liquid level; The controller is used to determine the change in the reference signal based on the current reference signal and the reference reference signal, determine the change in the measurement signal based on the current liquid level measurement signal and the measurement reference signal, compensate the change in the measurement signal using the change in the reference signal as a normalization reference to obtain the compensated liquid level feature value, and determine the real-time liquid level according to the preset correspondence.

[0009] Optionally, the shutdown response parameter includes the shutdown response time from the time the controller outputs the shutdown command to the time when the controllable drain valve actually stops draining; The controller is used to determine the current liquid level drop rate and the previous liquid level drop rate during the drainage process, based on the current time window and the continuous real-time liquid level in the preceding time window, respectively, and to determine the liquid level drop rate change rate based on the current liquid level drop rate, the previous liquid level drop rate, and the time interval between the two time windows; the controller is also used to obtain the stable residual liquid level after the controllable drainage valve actually stopped draining during the previous drainage process, and to determine the feedback correction amount based on the difference between the target stopped drainage liquid level and the stable residual liquid level; The controller determines the expected delayed liquid level drop based on the current liquid level drop rate, the rate of change of the liquid level drop rate, the shutdown response time, and the feedback correction amount. It determines the dynamic early shutdown liquid level based on the sum of the target stop drainage liquid level and the expected delayed liquid level drop amount. When the real-time liquid level drops to the dynamic early shutdown liquid level, it outputs the shutdown command to the controllable drainage valve.

[0010] Optionally, the co-emission system also includes: A pressure sensor is installed in at least one of the intermediate gas-liquid separator and the final gas-liquid separator to acquire a pressure signal characterizing the internal pressure of the corresponding gas-liquid separator. The discharge end of the corresponding drain channel is connected to a condensate discharge pipeline with a preset discharge end pressure. The controller is pre-configured to determine the discharge pressure differential based on the pressure signal and the preset discharge end pressure. When the change in the pressure signal exceeds the preset pressure change threshold during a single discharge process, the controller determines the pressure change rate based on the continuously acquired pressure signal, predicts the pressure change sequence within the shutdown response time, and divides the shutdown response time into multiple prediction sub-periods corresponding to different pressure ranges according to the pressure change sequence. Based on the discharge pressure differential corresponding to each prediction sub-period, the controller determines the corresponding liquid level drop rate correction coefficient, corrects the predicted liquid level drop rate within the corresponding prediction sub-period based on the liquid level drop rate correction coefficient, determines the pressure correction base drop amount based on the product of each corrected predicted liquid level drop rate and the duration of the corresponding prediction sub-period, and determines the expected delayed liquid level drop amount based on the pressure correction base drop amount and the feedback correction amount.

[0011] Optionally, the exhaust end of the primary compressor is connected to the intercooler through a primary exhaust pipe, and the primary exhaust pipe is provided with a primary exhaust temperature sensor, a primary exhaust venturi tube and a primary expansion joint in sequence along the gas flow direction. The outlet of the intermediate cooler is connected to the gas-liquid inlet of the intermediate gas-liquid separator; The gas phase outlet of the intermediate gas-liquid separator is connected to the inlet of the secondary compressor through an intermediate stage inlet pipe equipped with an intermediate elastic joint. The exhaust end of the secondary compressor is connected to the aftercooler through a secondary exhaust pipe. The secondary exhaust pipe is provided with a secondary exhaust venturi tube, a secondary expansion joint and an exhaust check valve in sequence along the gas flow direction. The outlet of the aftercooler is connected to the gas-liquid inlet of the final gas-liquid separator.

[0012] Optionally, the bottom drain port of at least one of the intermediate gas-liquid separator and the final gas-liquid separator is connected to the drain channel; The drainage channel is equipped with a controllable drainage valve, a manual shut-off valve, a filter element for intercepting particulate impurities in the condensate, a check valve element for preventing the discharged medium from flowing back into the corresponding gas-liquid separator, and an electromagnetic shut-off valve. The manual shut-off valve is used to isolate the drain channel when the controllable drain valve or the filter element is under maintenance, and the outlet of the drain channel is connected to the condensate discharge pipeline.

[0013] Optionally, the intake assembly includes a filter and an intake valve arranged sequentially along the gas flow direction, and the outlet of the intake valve is connected to the gas inlet of the primary compressor.

[0014] Optionally, the exhaust end of the secondary compressor is further provided with a venting branch, the venting branch being provided with a venting valve and a venting silencer located downstream of the venting valve; The controller is used to control the intake valve to reduce its opening and control the vent valve to open when the system is unloaded, so as to release air through the vent valve. The intercooler is connected to an intermediate safety valve, and the aftercooler is connected to an exhaust safety valve to limit the pressure of the intermediate stage air passage and the secondary exhaust air passage, respectively.

[0015] Secondly, embodiments of this disclosure provide a gas compression device, including: a multi-stage compressed gas condensate co-discharge system as described in any of the foregoing embodiments.

[0016] Compared with the prior art, the technical solution of the embodiments of the present invention has the following advantages: In the multi-stage compressed gas condensate coordinated discharge system provided in this invention embodiment, the condensate generated after the compressed gas is cooled by the intermediate cooler and the aftercooler can be collected in the annular collection space of the intermediate gas-liquid separator and / or the final gas-liquid separator, respectively. Since the reference detection unit is located below the target liquid seal level and remains aligned with the condensate during normal discharge, the reference signal output by the reference detection unit can reflect the changes in the equivalent dielectric parameters of the condensate caused by changes in water content, oil content, temperature, and impurity ratio. The controller compensates for this change in the liquid level measurement signal, reducing the interference of condensate dielectric property changes on the liquid level detection results. Based on this, the controller opens the controllable discharge valve when the compensated real-time liquid level reaches the discharge start level, matching the discharge action with the actual condensate accumulation and reducing invalid openings caused by fixed-cycle discharge. Simultaneously, the controller determines the liquid level drop rate based on the continuous real-time liquid level during discharge and, in conjunction with the controllable discharge valve's closing response parameters, determines the dynamic early closing timing, ensuring the valve receives a closing command before reaching the target stop discharge level, thereby compensating for delayed discharge that still occurs during the valve closing response period. This reduces condensate residue and prevents excessive drainage from damaging the liquid seal and causing compressed gas leakage, thereby reducing the operating frequency of the controllable drain valve and extending its service life. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of a multi-stage compressed gas condensate co-discharge system according to an embodiment of this disclosure; Figure 2 This is a schematic diagram of the structure of a gas-liquid separator according to an embodiment of the present disclosure; Figure 3 This is a schematic diagram of the specific structure of a multi-stage compressed gas condensate co-discharge system in an embodiment of this disclosure. Detailed Implementation

[0018] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0019] As can be seen from the background technology, drainage operations are currently performed at a fixed frequency.

[0020] However, in actual operation, there are situations where the current amount of condensate generated is small, and the drain valve is frequently opened. On the one hand, frequent energization of the controllable drain valve will increase power consumption and accelerate the aging of the coil, valve core, and seals; on the other hand, keeping the valve open when the condensate has been basically drained can easily cause compressed gas to leak through the drain channel, resulting in unnecessary pressure and compressed gas loss.

[0021] To address the aforementioned technical problems, this disclosure provides a multi-stage compressed gas condensate coordinated discharge system. The controller determines the liquid level drop rate based on the continuous real-time liquid level during discharge and, in conjunction with the closing response parameters of the controllable discharge valve, determines the dynamic early closing timing. This ensures the valve receives a closing command before reaching the target stopping discharge level, thereby compensating for any delayed discharge that still occurs during the valve's closing response. This reduces condensate residue and prevents excessive discharge from damaging the liquid seal and causing compressed gas leakage, thus reducing the operating frequency of the controllable discharge valve and extending its service life.

[0022] See Figure 1 and Figure 2 , Figure 1 This is a schematic diagram of a multi-stage compressed gas condensate coordinated discharge system according to an embodiment of this disclosure. Figure 2 This is a schematic diagram of the structure of a gas-liquid separator according to an embodiment of this disclosure.

[0023] The multi-stage compressed gas condensate co-discharge system may include: an intake assembly 110, a primary compressor 120, an intercooler 130, an intermediate gas-liquid separator 140, a secondary compressor 150, an aftercooler 160, and a final gas-liquid separator 170, which are connected sequentially along the gas flow direction.

[0024] At least one of the intermediate gas-liquid separator 140 and the final gas-liquid separator 170 includes a housing 210, a gas guide pipe 220 disposed within the housing 210, and a liquid distribution plate 250 disposed below the gas guide pipe 220. A liquid collection space S (i.e., the space formed by the liquid distribution plate 250 and the housing 210) is formed below the liquid distribution plate 250.

[0025] The housing is provided with a gas-liquid inlet IN and a gas phase outlet OUT. The gas guide pipe 220 is used to guide the gas-liquid mixture passing through the gas-liquid inlet IN to the liquid separator 250. The gas phase outlet OUT is connected to the gas phase space of the housing 210 located above the liquid separator 250. The liquid collection space S is connected to a drain channel 230, and the drain channel 230 is provided with a controllable drain valve 240.

[0026] The liquid collection space S is provided with a liquid level detection component, which includes a reference detection unit 252 and a liquid level measurement unit 254. The reference detection unit 252 is located below the target liquid seal level and is used to output a reference signal characterizing the equivalent dielectric parameter of the condensate. The liquid level measurement unit 254 is used to output a liquid level measurement signal characterizing the liquid level of the condensate in the liquid collection space S.

[0027] Specifically, the gas guide tube 220 can be made of metal tubing; in one embodiment, the gas guide tube 220 is made of copper tubing. Copper tubing has good thermal conductivity and processing properties, which is beneficial for the further condensation of residual vapor in the gas near the tube wall.

[0028] The housing 210 can be made of steel, stainless steel or other metal materials that can withstand the corresponding working pressure.

[0029] The liquid collection space S forms a volume capable of storing condensate, at least in the lower part of the gas-liquid separator.

[0030] In this embodiment, the gas-liquid inlet IN is connected to the gas guide pipe 220, so that the gas-liquid mixture discharged from the cooler first enters the gas guide pipe 220.

[0031] In one embodiment, the gas-liquid mixture flows downward along the gas guide pipe 220 and enters the liquid collection space S through the lower opening of the gas guide pipe 220. When the medium enters the liquid collection space S with a large cross-sectional area through the gas guide pipe 220, the flow velocity decreases and the flow direction changes, causing the denser droplets to separate from the airflow under the action of inertia and gravity.

[0032] The separated condensate settles downwards and is stored in the lower part of the collection space S. The separated gas flows upwards within the collection space S and is discharged from the gas phase outlet OUT located at the upper part of the collection space S.

[0033] Furthermore, the bottom of the housing 210 is provided with a bottom drain port, which is connected to the drain channel 230. The condensate accumulated in the liquid collection space S can enter the drain channel 230 through the bottom drain port.

[0034] Accordingly, the final stage gas-liquid separator can adopt the same or similar structure as the intermediate gas-liquid separator. The intermediate gas-liquid separator and the final stage gas-liquid separator can have different volumes, operating pressures, drain port sizes, and controllable drain valve specifications to adapt to the condensate generation and pressure conditions of different compression stages.

[0035] The controller 180 is connected to the reference detection unit 252, the liquid level measurement unit 254, and the controllable drain valve 240. It is used to compensate the liquid level measurement signal according to the reference signal to determine the real-time liquid level, control the controllable drain valve 240 to open when the real-time liquid level reaches the drain start liquid level, determine the liquid level drop rate according to the real-time liquid level continuously acquired during the draining period, determine the dynamic early closing timing according to the liquid level drop rate and the closing response parameters of the controllable drain valve, and output a closing command to the controllable drain valve 240.

[0036] Specifically, the gas first flows into the air intake assembly 110, which can filter the gas and purify it.

[0037] After the primary compressor 120 performs initial compression on the gas, the gas temperature will rise. The intercooler 130 then cools the gas to lower its temperature.

[0038] For example, the high-temperature compressed gas enters the intercooler 130 and exchanges heat with the cooling medium.

[0039] In one embodiment, the intercooler 130 reduces the temperature of the compressed gas from about 200°C to about 50°C to 60°C. As the temperature of the compressed gas decreases, moisture that was originally in vapor form condenses and, together with any oil mist that may be carried in the gas, forms condensate.

[0040] The cooled compressed gas and condensate enter the intermediate gas-liquid separator 140 through the outlet of the intercooler 130. The intermediate gas-liquid separator 140 can separate the condensate from the compressed gas, and the separated compressed gas can enter the secondary compressor 150.

[0041] The secondary compressor 150 further compresses the air using a compression mechanism similar to that of the primary compressor 120, thereby forming compressed air that meets the usage requirements.

[0042] Then, the aftercooler 160 performs a cooling operation, and the final gas-liquid separator 170 can perform a gas-liquid separation operation.

[0043] During this process, the reference detection unit 252 can provide the controller 180 with a reference signal characterizing the equivalent dielectric parameter of the condensate, and the liquid level measurement unit 254 can provide the controller 180 with a liquid level measurement signal characterizing the liquid level of the condensate in the liquid collection space S.

[0044] The controller 180 can compensate the liquid level measurement signal according to the reference signal to determine the real-time liquid level. When the real-time liquid level reaches the discharge start liquid level, it outputs a control signal to open the controllable discharge valve 240.

[0045] During the drainage process, the controller 180 can determine the rate of liquid level drop based on the continuously acquired real-time liquid level, determine the dynamic early closing timing based on the rate of liquid level drop and the closing response parameters of the controllable drainage valve, and output a closing command to the controllable drainage valve 240.

[0046] In this way, condensate residue can be reduced, and excessive drainage can be avoided to prevent damage to the liquid seal and leakage of compressed gas, thereby reducing the operating frequency of the controllable drain valve and extending its service life.

[0047] See next Figure 2 The liquid level detection assembly includes a reference electrode and a measuring electrode spaced apart along the axial direction of the housing 210, with the measuring electrode located above the reference electrode. The reference electrode constitutes the reference detection unit 252, and the plurality of measuring electrodes constitute the liquid level measuring unit 254. The reference electrode and the measuring electrode respectively form a capacitance detection circuit with a common electrode, which is the housing. The reference electrode is located below the target liquid seal level, and the measuring electrodes are distributed sequentially along the direction from the target liquid seal level toward the discharge start level.

[0048] In this embodiment, the reference electrode and the measuring electrode respectively form a capacitance detection circuit with the common electrode, and the common electrode is the housing 210; the reference electrode is disposed below the target liquid seal level, and the measuring electrodes are distributed sequentially along the direction from the target liquid seal level toward the drain start level.

[0049] The target liquid seal level refers to the minimum working liquid level set to keep the drain port or drain channel inlet submerged in condensate. Maintaining this liquid seal reduces the probability of compressed gas directly entering the drain channel.

[0050] In one embodiment, the housing 210 serves as a common electrode, and the reference electrode and each measuring electrode form a capacitance detection circuit with the housing 210. In another embodiment, the common electrode is a cylindrical electrode or a strip electrode independently disposed within the liquid collection space S.

[0051] The reference electrode is located entirely below the target liquid seal level. When draining according to normal control logic, even when the draining process is nearing completion, the collection space S still retains condensate at a level no lower than the target liquid seal level. Therefore, the reference electrode is always in the area surrounded by condensate.

[0052] Because the reference electrode remains submerged during normal operation, its detection signal primarily varies with the equivalent dielectric parameter of the current condensate, rather than changing significantly depending on whether the liquid level covers the reference electrode. Therefore, the reference electrode can provide a dielectric parameter compensation benchmark for multiple measuring electrodes.

[0053] Multiple measuring electrodes are sequentially distributed along the direction from the target liquid seal level to the discharge start level. When the liquid level rises or falls, the proportion of condensate covering the corresponding area of ​​each measuring electrode changes, causing a corresponding change in the measuring capacitance. In this way, measuring electrodes at different heights can respond sequentially to changes in liquid level, thereby enabling segmented liquid level measurement while achieving dielectric parameter reference detection, thus improving the stability of liquid level detection.

[0054] In some embodiments, the controller pre-stores a reference reference signal corresponding to the reference detection unit, a measurement reference signal corresponding to the liquid level measurement unit, and a preset correspondence between the compensated liquid level feature value and the liquid level. The controller is used to determine the change in the reference signal based on the current reference signal and the reference reference signal, determine the change in the measurement signal based on the current liquid level measurement signal and the measurement reference signal, compensate the change in the measurement signal using the change in the reference signal as a normalization reference to obtain the compensated liquid level feature value, and determine the real-time liquid level based on the preset correspondence.

[0055] Specifically, the controller pre-stores reference signals. Measurement reference signals corresponding to each measuring electrode Among them, the reference signal This can be used to measure the capacitance value of the reference electrode when the gas-liquid separator is in a liquid-free state or when a known medium is used for calibration; and to measure the reference signal. For the first under the same calibration state The capacitance value corresponding to each measuring electrode.

[0056] During operation, the controller acquires the current reference signal. and the Current liquid level measurement signal of each measuring electrode And determine them respectively: .

[0057] in, The change in the reference signal For the first The change in the measurement signal corresponding to each measurement electrode.

[0058] When the reference electrode is completely immersed in the condensate, the change in the reference signal It is related to the degree of dielectric change of the condensate relative to the gaseous medium. Changes in the measurement signal of each measuring electrode It is also affected by the dielectric parameters of the condensate and the proportion of the area corresponding to the measuring electrode covered by the condensate.

[0059] To reduce the impact of changes in the dielectric parameters of the condensate, the controller can determine the first [value] according to the following relationship. Normalized liquid level characteristic value of each measuring electrode : .

[0060] in, For the first The calibration coefficients corresponding to the first measuring electrode are used to compensate for the difference between the reference electrode and the first electrode. The differences between the measuring electrodes in terms of area, location, insulation layer thickness, and edge electric field.

[0061] Accordingly, the controller can normalize the liquid level characteristic value The value is limited to between 0 and 1, and the value after the limitation is used as the first value. Liquid coverage ratio of each measurement section ,Right now .

[0062] When each measuring electrode corresponds to a height of When the liquid level is in the specified range, the real-time liquid level The following relationship can be used to determine this: .

[0063] in, Where N is the reference height of the lowest measurement section, and N is the number of measurement electrodes. For the first The height of the liquid level section corresponding to each measuring electrode.

[0064] In other implementations, the controller can form a feature vector based on multiple normalized liquid level feature values ​​and determine the real-time liquid level using a pre-calibrated lookup table, piecewise linear function, or polynomial mapping relationship. All of the above implementations use changes in the reference signal to compensate for changes in the measured signal.

[0065] In some implementations, the controller only opens the controllable drain valve when the real-time liquid level continuously reaches or exceeds the drain start level for a preset confirmation time. This ensures relatively consistent measurement results for the same liquid level under different condensate dielectric properties, thereby improving the accuracy of drain start judgment and dynamic early shutdown judgment, and reducing the occurrence of erroneous, premature, or delayed opening of the controllable drain valve.

[0066] In some embodiments, the shut-off response parameters include the shut-off response time from the time the controller outputs the shut-off command to the time when the controllable drain valve actually stops draining; the controller is used to determine the current liquid level drop rate and the previous liquid level drop rate during the draining process, based on the current time window and the continuous real-time liquid level in the preceding time window, respectively, and to determine the liquid level drop rate change rate based on the current liquid level drop rate, the previous liquid level drop rate, and the time interval between the two time windows; the controller is also used to obtain the stable residual liquid level after the controllable drain valve actually stops draining during the previous draining process, and to determine the feedback correction amount based on the difference between the target stop draining liquid level and the stable residual liquid level; the controller determines the expected delayed liquid level drop amount based on the current liquid level drop rate, the liquid level drop rate change rate, the shut-off response time, and the feedback correction amount, determines the dynamic early shut-off liquid level based on the sum of the target stop draining liquid level and the expected delayed liquid level drop amount, and outputs the shut-off command to the controllable drain valve when the real-time liquid level drops to the dynamic early shut-off liquid level.

[0067] Specifically, when the real-time liquid level Reaching the start-up liquid level for drainage When the start-up confirmation conditions are met, the controller outputs an opening command to the controllable drain valve. The controllable drain valve can be a solenoid valve, a pneumatic solenoid valve, or a drain valve driven by an electric actuator.

[0068] After the controllable drain valve opens, the internal pressure of the gas-liquid separator forces the condensate to be discharged through the bottom drain port and drain channel. The controller operates according to a preset sampling cycle. Continuously acquire real-time liquid level.

[0069] To determine the downward trend of the liquid level, the controller sets the current time window. and preceding time window Current time window For the most recent Liquid level data over a period of time, preceding time window Before the current time window Liquid level data over a period of time.

[0070] For the current time window Multiple liquid level sampling points inside ( , By performing linear fitting, the slope of the current liquid level change can be obtained. : .

[0071] Due to the overall drop in liquid level during drainage, The value is negative. The controller will record the current rate of liquid level decrease. Determined as: .

[0072] Similarly, the controller determines the preceding liquid level descent rate based on the liquid level data within the preceding time window Wp. .

[0073] Assume the center times of the current time window and the preceding time window are respectively and The rate of change of the liquid level drop The following relationship can be used to determine this: .

[0074] when A value greater than zero indicates that the drainage rate is increasing; when... A value less than zero indicates that the drainage rate is slowing down; when When it approaches zero, it indicates that the drainage rate is basically stable at the current stage.

[0075] Close response time of controllable drain valve This refers to the time between the controller outputting a shut-off command and the controllable drain valve actually stopping draining.

[0076] Close response time This may include the control signal transmission time, the electromagnetic coil demagnetization time, the time it takes for the valve core to move from the open position to the closed position, and the time it takes for the remaining condensate in the drain channel to continue flowing out after the valve core is closed.

[0077] Among them, the shutdown response time The data can be pre-measured and stored in the controller during equipment factory calibration, or updated based on historical drainage data during equipment operation.

[0078] In one approach, the controller records the moment the output shutdown command is issued. And when the subsequent rate of liquid level decline continuously falls below the preset stable rate threshold and reaches the preset stable confirmation time, the corresponding time will be determined as the actual time to stop draining. .

[0079] The actual shutdown response time The following relationship can be used to determine this: .

[0080] The controller can perform a weighted average of the actual shut-off response times corresponding to multiple drainage cycles to update the shut-off response times used in subsequent drainage processes. .For example: .

[0081] Here, α is the time update weight, which is greater than 0 and less than 1. The larger α is, the smoother the change in the closing response time; the smaller α is, the faster the controller responds to changes in the current valve state.

[0082] Even after the controllable drain valve actually stops draining, the liquid level may continue to fluctuate due to inertial flow, bubble release, and housing vibration. Therefore, the controller can wait for a preset stabilization waiting time and determine the corresponding liquid level as the stable residual liquid level when the rate of change of liquid level is lower than the stabilization threshold. .

[0083] The controller stores the target stop drainage level. The target is to stop the drainage level. It is preferable to have a liquid level higher than or equal to the target liquid seal level so that the bottom drain port remains submerged in condensate after the drainage is completed.

[0084] During the current drainage cycle, the controller adjusts the residual liquid level based on the stable level from the previous drainage process. Determine the feedback correction amount: .

[0085] When the stable residual liquid level of the previous drainage cycle Below the target stop drainage level At that time, feedback correction amount A positive value indicates that the shutdown command needs to be output earlier for this drainage operation.

[0086] When the stable residual liquid level of the previous drainage cycle The liquid level is higher than the target level for stopping drainage. At that time, feedback correction amount A negative value indicates that the output of the shut-off command can be appropriately delayed for this drainage operation.

[0087] The controller adjusts according to the current rate of liquid level drop. Rate of change of liquid level descent Closing response time and feedback correction amount Determine the expected delayed drop in liquid level: .

[0088] in, This indicates the liquid level that is expected to continue to fall during the shutdown response period, assuming the rate of liquid level decline remains constant at its current value. This indicates the additional drop in liquid level caused by the changing trend of the drainage rate. This indicates the feedback correction amount based on the final residual liquid level of the previous cycle.

[0089] Furthermore, the controller can also limit the expected delayed drop in liquid level to a preset minimum value. and preset maximum value This is to avoid premature shutdown correction caused by sensor failure or sudden pressure changes.

[0090] Accordingly, the liquid level is dynamically and prematurely shut off. Determined according to the following relationship: .

[0091] As the liquid level drops from a higher position to a lower position during the drainage process, the liquid level is dynamically and prematurely shut off. The liquid level is higher than the target level for stopping drainage. When the real-time liquid level H drops to At that time, the controller immediately outputs a shut-off command to the controllable drain valve.

[0092] Close response time Inside, the controllable drain valve has not completely stopped draining, and the liquid level continues to drop by approximately [missing information]. When the controllable drain valve actually stops draining, the liquid level is theoretically close to the target stop draining level. .

[0093] In the above scheme, the determined estimated delayed liquid level drop, determined by the combined effect of current liquid level decline trend prediction and historical drainage results feedback, can adapt to both current operating conditions and long-term changes. This enables the dynamically pre-closing liquid level to have adaptive correction capabilities, improves the consistency of the final residual liquid level in each drainage cycle, and avoids insufficient or excessive drainage under different operating conditions due to a fixed pre-closing liquid level.

[0094] In some embodiments, the coordinated discharge system further includes: a pressure sensor disposed in at least one of the intermediate gas-liquid separator and the final gas-liquid separator, for acquiring a pressure signal characterizing the internal pressure of the corresponding gas-liquid separator, wherein the discharge end of the corresponding discharge channel is connected to a condensate discharge pipeline having a preset discharge end pressure; the controller is configured to pre-determine the discharge pressure differential based on the pressure signal and the preset discharge end pressure; when the change in the pressure signal exceeds a preset pressure change threshold during a single discharge process, the controller is configured to determine the pressure change rate based on the continuously acquired pressure signal, predict the pressure change sequence within the shutdown response time, and divide the shutdown response time into multiple prediction sub-periods corresponding to different pressure ranges according to the pressure change sequence; determine a corresponding liquid level drop rate correction coefficient based on the discharge pressure differential corresponding to each prediction sub-period, correct the predicted liquid level drop rate within the corresponding prediction sub-period based on the liquid level drop rate correction coefficient, determine the pressure correction basis drop amount based on the product of each corrected predicted liquid level drop rate and the duration of the corresponding prediction sub-period, and determine the expected delayed liquid level drop amount based on the pressure correction basis drop amount and the feedback correction amount.

[0095] Specifically, under certain operating conditions, the internal pressure of the gas-liquid separator remains basically stable during the liquid discharge process. The expected delayed liquid level drop can be determined by using the current liquid level drop rate, the rate of change of the liquid level drop rate, and the shutdown response time.

[0096] However, when the compressor is loading, unloading, venting, or when the downstream gas consumption changes rapidly, the internal pressure of the gas-liquid separator may change significantly during the drainage process. This pressure change alters the rate at which condensate is discharged through the controllable drain valve and drain channel.

[0097] Therefore, a pressure sensor can be installed in the gas-liquid separator. The pressure sensor detects the internal pressure of the gas-liquid separator. The pressure at the discharge end of the drain channel. It can be detected by another pressure sensor.

[0098] Then the pressure difference : .

[0099] The controller pre-stores the discharge pressure differential. Correction factor for liquid level drop rate The correspondence between them. The correspondence can be calibrated through prototype testing and stored in the form of a lookup table.

[0100] When the pressure change detected during a single drainage process does not exceed the preset pressure change threshold, the controller can use a single correction coefficient corresponding to the current pressure to correct the expected delayed liquid level drop.

[0101] When the pressure change exceeds the preset pressure change threshold, the controller determines the current pressure change rate based on the continuous pressure signal. And predict the shutdown response time. The internal pressure change process.

[0102] In one linear prediction method, the prediction pressure at time τ after the instruction output is turned off is: .

[0103] in, Due to current pressure, The current rate of change of pressure, τ, ranges from 0 to... .

[0104] The controller will disable response time. The prediction is divided into M sub-time periods, each with a duration of [duration missing]. For the first Determine the forecast pressure for each forecast sub-period. Predicting the discharge pressure difference and corresponding correction factors .

[0105] No. The predicted liquid level decline rate within each predicted sub-period is: .

[0106] in, For the first The representative moment of each predicted sub-period.

[0107] Pressure Correction Base Decrease for: .

[0108] Subsequently, the controller adds the feedback correction amount to the pressure correction base decrease amount, resulting in: .

[0109] By segmenting and predicting the pressure and level drop rates within the shutdown response time, it is possible to avoid calculating the total delayed drop based on the single instantaneous discharge rate at the time of the shutdown command when the pressure continues to rise or fall.

[0110] In some embodiments, both the intermediate gas-liquid separator and the final gas-liquid separator are equipped with a liquid level detection component, a drain channel, and a controllable drain valve, and the controllable drain valve is controlled by a controller.

[0111] See Figure 1 and Figure 3 , Figure 3 This is a schematic diagram of the specific structure of a multi-stage compressed gas condensate co-discharge system in an embodiment of this disclosure.

[0112] The intake assembly 110 may include a filter 112 and an intake valve arranged sequentially along the gas flow direction, and the outlet of the intake valve 114 is connected to the gas inlet of the primary compressor 120.

[0113] Outside air passes through filter 112, where larger particles are intercepted. The air then passes through intake valve 114 and enters the primary compressor unit 120.

[0114] The intake valve 114 can be an intake control valve with opening adjustment function, or a pneumatic valve or an electric control valve that switches between loading and unloading states.

[0115] Accordingly, the exhaust end of the secondary compressor host 150 is also provided with a venting branch 193, the venting branch 193 is provided with a venting valve 194 and a venting silencer 195 located downstream of the venting valve 194.

[0116] The controller is used to control the intake valve to reduce its opening and the vent valve to open when the system is unloaded, so as to release air through the vent valve.

[0117] The intercooler 130 is connected to an intermediate safety valve F1, and the aftercooler 160 is connected to an exhaust safety valve F2 to limit the pressure of the intermediate stage air passage and the secondary exhaust air passage, respectively.

[0118] The exhaust end of the primary compressor 120 is connected to the intercooler 130 through the primary exhaust pipe 122. The primary exhaust pipe 122 is provided with a primary exhaust temperature sensor 124, a primary exhaust venturi tube 126 and a primary expansion joint 128 in sequence along the gas flow direction.

[0119] The primary exhaust temperature sensor 124 is used to detect the exhaust temperature of the primary compressor 120. The primary exhaust venturi tube 126 can be used for airflow parameter detection, airflow rectification, or to form a predetermined flow state. The primary expansion joint 128 is used to absorb the thermal expansion of the primary exhaust pipe 122 caused by high temperature and to reduce the vibration of the primary compressor 120 transmitted to the intercooler 130.

[0120] The outlet of the intercooler 130 is connected to the gas-liquid inlet of the intermediate gas-liquid separator 140.

[0121] The gas phase outlet of the intermediate gas-liquid separator 140 is connected to the air inlet of the secondary compressor 150 through an intermediate stage air inlet pipe 191 equipped with an intermediate elastic joint 192.

[0122] The intermediate elastic joint can absorb installation deviations, vibration displacements, and thermal displacements between the intermediate gas-liquid separator, the secondary compressor, and related pipelines.

[0123] The secondary compression unit 150 performs secondary compression on the compressed gas.

[0124] The exhaust end of the secondary compressor 150 is connected to the aftercooler 160 through the secondary exhaust pipe 151. The secondary exhaust pipe 151 is provided with a secondary exhaust venturi pipe 152, a secondary expansion joint 153 and an exhaust check valve 154 in sequence along the gas flow direction. The outlet of the aftercooler 160 is connected to the gas-liquid inlet of the final gas-liquid separator 170.

[0125] The exhaust check valve 154 is used to prevent compressed gas in the aftercooler 160 or downstream pipeline from flowing back into the secondary compressor 150. The secondary expansion joint 153 is used to absorb thermal displacement and mechanical vibration of the secondary exhaust pipeline 151.

[0126] In some embodiments, the secondary exhaust pipe 151 is further provided with a secondary exhaust temperature sensor 155 and a secondary exhaust pressure sensor 156.

[0127] In some embodiments, the bottom drain port of at least one of the intermediate gas-liquid separator and the final gas-liquid separator is connected to the drain channel.

[0128] The drain channel is equipped with a controllable drain valve, a manual shut-off valve, a filter element for intercepting particulate impurities in the condensate, a check valve for preventing the discharged medium from flowing back into the corresponding gas-liquid separator, and an electromagnetic shut-off valve. The manual shut-off valve is used to isolate the drain channel when the controllable drain valve or the filter element is under maintenance. The outlet of the drain channel is connected to the condensate discharge pipeline.

[0129] In one example, the drain channel is provided with a first controllable drain valve 141, a first manual shut-off valve 145, a first filter element 142, a first check valve 143, and a first electromagnetic shut-off valve 144.

[0130] In one example, the drain channel is provided with a second controllable drain valve 171, a second manual shut-off valve 174, a second filter element 172, and a second electromagnetic shut-off valve 173.

[0131] In some embodiments, the multi-stage compressed gas condensate co-discharge system further includes a first temperature sensor 147 and a first pressure sensor 146 connected to the intermediate gas-liquid separator 140.

[0132] A second temperature sensor 176 and a second pressure sensor 175 are connected to the final gas-liquid separator 170.

[0133] It is understood that the above embodiments provide multiple implementation schemes, and these implementation schemes can be combined and cross-referenced with each other without conflict, thereby extending to multiple possible implementation schemes. These can all be considered as the implementation schemes disclosed and made public in this application.

[0134] This disclosure also provides a gas compression device, which includes the multi-stage compressed gas condensate co-discharge system described in any of the foregoing embodiments.

[0135] While this specification discloses the invention as described above, the invention is not limited thereto. Any person skilled in the art can make various modifications and alterations without departing from the spirit and scope of the invention; therefore, the scope of protection of this invention should be determined by the scope defined in the claims.

Claims

1. A multi-stage compressed gas condensate co-discharge system, characterized in that, include: The following components are connected sequentially along the gas flow direction: intake assembly, primary compressor, intercooler, intermediate gas-liquid separator, secondary compressor, aftercooler, and final gas-liquid separator. At least one of the intermediate gas-liquid separator and the final gas-liquid separator includes a housing, a gas guide pipe disposed within the housing, and a liquid distribution plate disposed below the gas guide pipe, with a liquid collection space formed below the liquid distribution plate; the housing has a gas-liquid inlet and a gas phase outlet, the gas guide pipe is used to guide the gas-liquid mixture passing through the gas-liquid inlet to the liquid distribution plate, and the gas phase outlet communicates with the gas phase space of the housing located above the liquid distribution plate; the liquid collection space is connected to a drain channel, and the drain channel is provided with a controllable drain valve; a liquid level detection component is provided in the liquid collection space, the liquid level detection component includes a reference detection unit and a liquid level measurement unit, the reference detection unit is located below the target liquid seal level and is used to output a reference signal characterizing the equivalent dielectric parameter of the condensate, and the liquid level measurement unit is used to output a liquid level measurement signal characterizing the liquid level of the condensate in the annular liquid collection space; The controller is configured to compensate the liquid level measurement signal according to the reference signal to determine the real-time liquid level, control the controllable drain valve to open when the real-time liquid level reaches the drain start liquid level, determine the liquid level drop rate according to the real-time liquid level continuously acquired during the draining period, determine the dynamic early closing timing according to the liquid level drop rate and the closing response parameters of the controllable drain valve, and output a closing command to the controllable drain valve.

2. The coordinated emission system according to claim 1, characterized in that, The liquid level detection assembly includes a reference electrode and a measuring electrode spaced apart along the axial direction of the housing, with the measuring electrode located above the reference electrode. The reference electrode constitutes the reference detection unit, and the plurality of measuring electrodes constitute the liquid level measuring unit. The reference electrode and the measuring electrode, together with the common electrode, form a capacitance detection circuit, and the common electrode is the housing; the reference electrode is located below the target liquid seal level, and the measuring electrodes are distributed sequentially along the direction from the target liquid seal level toward the drain start level.

3. The coordinated emission system according to claim 1, characterized in that, The controller pre-stores the reference reference signal corresponding to the reference detection unit, the measurement reference signal corresponding to the liquid level measurement unit, and the preset correspondence between the compensation liquid level feature value and the liquid level; The controller is used to determine the change in the reference signal based on the current reference signal and the reference reference signal, determine the change in the measurement signal based on the current liquid level measurement signal and the measurement reference signal, compensate the change in the measurement signal using the change in the reference signal as a normalization reference to obtain the compensated liquid level feature value, and determine the real-time liquid level according to the preset correspondence.

4. The multi-stage compressed gas condensate co-discharge system according to claim 1, characterized in that, The shutdown response parameters include the shutdown response time from the time the controller outputs the shutdown command to the time when the controllable drain valve actually stops draining; The controller is used to determine the current liquid level drop rate and the previous liquid level drop rate during the drainage process, based on the current time window and the continuous real-time liquid level in the preceding time window, respectively, and to determine the liquid level drop rate change rate based on the current liquid level drop rate, the previous liquid level drop rate, and the time interval between the two time windows; the controller is also used to obtain the stable residual liquid level after the controllable drainage valve actually stopped draining during the previous drainage process, and to determine the feedback correction amount based on the difference between the target stopped drainage liquid level and the stable residual liquid level; The controller determines the expected delayed liquid level drop based on the current liquid level drop rate, the rate of change of the liquid level drop rate, the shutdown response time, and the feedback correction amount. It determines the dynamic early shutdown liquid level based on the sum of the target stop drainage liquid level and the expected delayed liquid level drop amount. When the real-time liquid level drops to the dynamic early shutdown liquid level, it outputs the shutdown command to the controllable drainage valve.

5. The coordinated emission system according to claim 4, characterized in that, Also includes: A pressure sensor is installed in at least one of the intermediate gas-liquid separator and the final gas-liquid separator to acquire a pressure signal characterizing the internal pressure of the corresponding gas-liquid separator. The discharge end of the corresponding drain channel is connected to a condensate discharge pipeline with a preset discharge end pressure. The controller is pre-configured to determine the discharge pressure differential based on the pressure signal and the preset discharge end pressure. When the change in the pressure signal exceeds the preset pressure change threshold during a single discharge process, the controller determines the pressure change rate based on the continuously acquired pressure signal, predicts the pressure change sequence within the shutdown response time, and divides the shutdown response time into multiple prediction sub-periods corresponding to different pressure ranges according to the pressure change sequence. Based on the discharge pressure differential corresponding to each prediction sub-period, the controller determines the corresponding liquid level drop rate correction coefficient, corrects the predicted liquid level drop rate within the corresponding prediction sub-period based on the liquid level drop rate correction coefficient, determines the pressure correction base drop amount based on the product of each corrected predicted liquid level drop rate and the duration of the corresponding prediction sub-period, and determines the expected delayed liquid level drop amount based on the pressure correction base drop amount and the feedback correction amount.

6. The coordinated emission system according to claim 1, characterized in that, The exhaust end of the primary compressor is connected to the intercooler through a primary exhaust pipe. The primary exhaust pipe is provided with a primary exhaust temperature sensor, a primary exhaust venturi tube and a primary expansion joint in sequence along the gas flow direction. The outlet of the intermediate cooler is connected to the gas-liquid inlet of the intermediate gas-liquid separator; The gas phase outlet of the intermediate gas-liquid separator is connected to the inlet of the secondary compressor through an intermediate stage inlet pipe equipped with an intermediate elastic joint. The exhaust end of the secondary compressor is connected to the aftercooler through a secondary exhaust pipe. The secondary exhaust pipe is provided with a secondary exhaust venturi tube, a secondary expansion joint and an exhaust check valve in sequence along the gas flow direction. The outlet of the aftercooler is connected to the gas-liquid inlet of the final gas-liquid separator.

7. The coordinated emission system according to claim 1, characterized in that, The bottom drain port of at least one of the intermediate gas-liquid separator and the final gas-liquid separator is connected to the drain channel; The drainage channel is equipped with a controllable drainage valve, a manual shut-off valve, a filter element for intercepting particulate impurities in the condensate, a check valve element for preventing the discharged medium from flowing back into the corresponding gas-liquid separator, and an electromagnetic shut-off valve. The manual shut-off valve is used to isolate the drain channel when the controllable drain valve or the filter element is under maintenance, and the outlet of the drain channel is connected to the condensate discharge pipeline.

8. The coordinated emission system according to claim 1, characterized in that, The intake assembly includes a filter and an intake valve arranged sequentially along the gas flow direction, and the outlet of the intake valve is connected to the gas inlet of the primary compressor.

9. The coordinated emission system according to claim 8, characterized in that, The exhaust end of the secondary compressor is also provided with a venting branch, which is provided with a venting valve and a venting silencer located downstream of the venting valve. The controller is used to control the intake valve to reduce its opening and control the vent valve to open when the system is unloaded, so as to release air through the vent valve. The intercooler is connected to an intermediate safety valve, and the aftercooler is connected to an exhaust safety valve to limit the pressure of the intermediate stage air passage and the secondary exhaust air passage, respectively.

10. A gas compression device, characterized in that, include: The multi-stage compressed gas condensate co-discharge system as described in any one of claims 1 to 9.

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