A dual-output gas source device for nitrogen generation from instrument air

Abstract

This utility model discloses a dual-output air source device for instrument air and nitrogen generation, relating to the field of compressor maintenance technology. It includes a dual-unit air compressor, an oil-water separator, an adsorption dryer, a filtration system, a nitrogen generator, an instrument air storage tank, and a nitrogen storage tank. The dual-unit air compressor includes a first screw air compressor and a second screw air compressor. The inlet of the oil-water separator is connected to the outlet of the dual-unit air compressor, and the inlet of the adsorption dryer is connected to the outlet of the oil-water separator. The filtration system includes a first filter, a second filter, a third filter, and a fourth filter. The first and second filters are located at the inlet end of the adsorption dryer. This dual-output air source device can output clean, dry air and high-purity (99.98%) nitrogen, meeting the gas requirements of different equipment. The lifespan of the filter element (a vulnerable part) inside the adsorption dryer is greatly increased, reducing maintenance costs.

Description

Technical Field

[0001] This utility model specifically relates to an instrument air nitrogen generator with dual-output gas source, belonging to the field of compressor maintenance technology. Background Technology

[0002] In fields such as industrial automation, precision manufacturing, and scientific research, instrument air serves as a core air source for driving automated instruments, precision testing equipment, and cleanroom control. Its cleanliness, stability, and supply continuity directly impact production accuracy and operational safety. These air sources typically fall into two categories: first, clean compressed air, primarily used to drive pneumatic instruments, valves, and other equipment that do not directly contact the product; and second, high-purity nitrogen, widely used in chemical reaction protection, clean purging of electronic components, maintaining sterile environments in biopharmaceuticals, and creating inert atmospheres in laboratories. Nitrogen is particularly crucial in oxygen-sensitive processes, ensuring production safety and product quality.

[0003] With the continuous upgrading of industrial technology, single gas supply devices can no longer meet the complex needs of modern industry. Currently, the single compressed air or single nitrogen gas supply devices commonly used in existing technologies have significant limitations:

[0004] 1. The inability to simultaneously provide clean compressed air and high-purity nitrogen necessitates the installation of multiple independent systems to meet the gas requirements of different equipment. This not only increases equipment procurement and maintenance costs but also occupies more installation space and reduces system integration efficiency.

[0005] 2. Due to factors such as air compressor operation fluctuations and pipeline losses, the output pressure of existing air source devices is prone to fluctuations. Automated instruments and precision testing equipment have extremely high requirements for the stability of air source pressure. Pressure fluctuations may lead to problems such as instrument measurement errors and control failures, affecting production accuracy.

[0006] 3. In extreme situations such as sudden power outages, the existing equipment lacks an effective emergency gas supply guarantee mechanism and cannot continuously provide a stable gas source for downstream equipment. At this time, if precision instruments, sensitive experimental materials, etc. are exposed to unclean air or lose their inert protective atmosphere, it may cause equipment damage, material contamination, or even safety accidents (such as the oxidation risk caused by the introduction of oxygen in chemical reactions), seriously threatening production safety.

[0007] Therefore, developing an integrated gas source device that can simultaneously output clean compressed air and high-purity nitrogen, ensure stable gas source pressure, and provide emergency gas supply capability in the event of a power outage is key to solving the pain points of existing technologies and meeting the needs of efficient and safe industrial production. Utility Model Content

[0008] The purpose of this utility model is to address the shortcomings of existing technologies by providing a dual-output gas source device for instrument air and nitrogen generation. However, the gas source pressure stability is insufficient, and it cannot provide a continuous and stable gas source when there is a sudden power outage, which poses a safety hazard.

[0009] This utility model achieves the above-mentioned objective through the following technical solution: a dual-output air source device for instrument air and nitrogen generation, comprising a dual air compressor, an oil-water separator, an adsorption dryer, a filtration system, a nitrogen generator, an instrument air storage tank, and a nitrogen storage tank. The dual air compressor includes a first screw air compressor and a second screw air compressor. The inlet of the oil-water separator is connected to the outlet of the dual air compressor. The inlet of the adsorption dryer is connected to the outlet of the oil-water separator. The filtration system includes a first filter, a second filter, a third filter, and a fourth filter. The first and second filters are located at the inlet end of the adsorption dryer. Three filters are installed at the outlet of the nitrogen generator. The inlet of the nitrogen generator is connected to the outlet of the adsorption dryer. The instrument air storage tank is connected to the outlet of the adsorption dryer. A fourth filter is installed between the outlet of the adsorption dryer, the nitrogen generator, and the instrument air storage tank. The nitrogen storage tank is connected to the outlet of the nitrogen generator. The outlets of the instrument air storage tank and the nitrogen storage tank are respectively connected to the instrument air outlet and the nitrogen outlet. Pressure gauges and safety valves are installed on both the instrument air outlet and the nitrogen outlet. The outlet of the adsorption dryer is divided into two paths: one path connects to the instrument air storage tank, and the other path connects sequentially to the filtration system and the nitrogen generator. The outlet of the nitrogen generator is connected to the nitrogen storage tank.

[0010] Preferably, the dual air compressor is configured with a main unit and an auxiliary unit.

[0011] By adopting the above technical solution, air is compressed to 0.65-1.0MPa by a dual air compressor, and after the oil and water in the air are removed by an oil-water separator, it enters an adsorption refrigerated dryer for further drying.

[0012] Preferably, the air compressor is equipped with an air guide shroud.

[0013] By adopting the above technical solution, an air guide shroud is installed on the air compressor. Its function is to dissipate most of the heat discharged by the air compressor's exhaust fan, so as to avoid affecting the normal operation of the air compressor due to poor heat dissipation. In addition, the use of an air guide shroud can reduce the overall noise.

[0014] Preferably, the outlet of the adsorption dryer sequentially passes through a nitrogen generator to generate nitrogen gas, which then enters a nitrogen storage tank for use by downstream equipment.

[0015] By adopting the above technical solution, one stream of nitrogen enters the instrument air storage tank for storage, while the other stream passes through a filter and a module nitrogen generator to produce nitrogen with a purity of ≥99.98%, which is then stored in a nitrogen storage tank.

[0016] Preferably, valves are provided at the inlet of the dual air compressor, the inlet of the instrument air storage tank, and the inlet of the nitrogen generator to control the operation of the pipeline gas.

[0017] By adopting the above technical solution, it is convenient to control the switches and controls on each gas circuit.

[0018] Preferably, the first filter is a Class T filter with a filtration accuracy of 1 μm; the second and fourth filters are both Class A filters with a filtration accuracy of 0.01 μm; and the third filter is an AR class dust removal filter with a filtration accuracy of 0.01 μm.

[0019] By adopting the above technical solutions, impurities and dust can be filtered better during the filtration process, thereby improving the filtration accuracy.

[0020] Preferably, a flow meter is installed on the pipeline between the adsorption dryer and the nitrogen generator to monitor the gas flow rate.

[0021] By adopting the above technical solution, flow rate can be easily measured, and gas can be detected.

[0022] The beneficial effects of this utility model are:

[0023] 1. This instrument features a dual-output air source device for both air and nitrogen. The dual air source device can output clean, dry air and high-purity (99.98%) nitrogen to meet the gas requirements of different equipment. The service life of the filter element (a vulnerable part) inside the adsorption-type refrigerated dryer is greatly increased, reducing maintenance costs.

[0024] 2. This instrument air-nitrogen dual-output gas source device can provide a stable output of air and nitrogen for 1 to 2 hours, eliminating the danger caused by sudden power outages and sudden exposure of test materials to air, thus achieving the goal of safe production. The use of the separator can greatly reduce the size of the skid, making maintenance and transportation convenient. Attached Figure Description

[0025] Figure 1 This is a three-dimensional structural diagram of the appearance of this utility model;

[0026] Figure 2 This is a schematic diagram showing the connection between the first filter and the second filter in this utility model;

[0027] Figure 3 This is a schematic diagram showing the connection between the instrument air storage tank and the nitrogen storage tank in this utility model;

[0028] Figure 4 This is a schematic diagram of the structure of the third filter and the nitrogen storage tank in this utility model;

[0029] In the diagram: 1. Dual-screw air compressor; 101. First screw air compressor; 102. Second screw air compressor; 2. Oil-water separator; 3. Adsorption dryer; 4. Filtration system; 401. First filter; 402. Second filter; 403. Third filter; 404. Fourth filter; 5. Nitrogen generator; 6. Instrument air storage tank; 601. Instrument air outlet; 7. Nitrogen storage tank; 701. Nitrogen outlet. Detailed Implementation

[0030] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0031] Please see Figure 1 - Figure 4 As shown, a dual-output instrument air / nitrogen generator device includes: a dual air compressor 1, an oil-water separator 2, an adsorption dryer 3, a filtration system 4, a nitrogen generator 5, an instrument air storage tank 6, and a nitrogen storage tank 7. The dual air compressor 1 includes a first screw air compressor 101 and a second screw air compressor 102. The inlet of the oil-water separator 2 is connected to the outlet of the dual air compressor 1. The inlet of the adsorption dryer 3 is connected to the outlet of the oil-water separator 2. The filtration system 4 includes a first filter 401, a second filter 402, a third filter 403, and a fourth filter 404. The first filter 401 and the second filter 402 are located at the inlet of the adsorption dryer 3, and the third filter 403 is located at the outlet of the nitrogen generator 5. At the outlet, the inlet of nitrogen generator 5 is connected to the outlet of adsorption dryer 3, the instrument air storage tank 6 is connected to the outlet of adsorption dryer 3, a fourth filter 404 is installed between the outlet of adsorption dryer 3, nitrogen generator 5, and instrument air storage tank 6, nitrogen storage tank 7 is connected to the outlet of nitrogen generator 5, the outlets of instrument air storage tank 6 and nitrogen storage tank 7 are respectively connected to instrument air outlet 601 and nitrogen outlet 701, pressure gauges and safety valves are installed on instrument air outlet 601 and nitrogen outlet 701, the outlet of adsorption dryer 3 is divided into two paths, one path is connected to instrument air storage tank 6, and the other path is connected to filtration system 4 and nitrogen generator 5 in sequence, the outlet of nitrogen generator 5 is connected to nitrogen storage tank 7, and the air compressor of the dual air compressor 1 is set as main and auxiliary units.

[0032] Air is compressed to 0.65-1.0 MPa by a dual air compressor 1. After oil and water are removed by an oil-water separator, the air enters an adsorption-type refrigerated dryer for further drying, with an outlet pressure of 0.4-1.0 MPa. The dried air is then divided into two streams: one stream enters the instrument air storage tank 6 for storage, and the other stream passes through a filter and a module nitrogen generator to produce nitrogen with a purity of ≥99.98%.

[0033] Reference Figure 2 - Figure 3 An air guide hood is installed on the air compressor. The outlet of the adsorption dryer 3 passes through the nitrogen generator 5 to generate nitrogen gas, which enters the nitrogen storage tank 7 for use by downstream equipment.

[0034] Reference Figure 2 - Figure 3 The inlet of the dual air compressor 1, the instrument air storage tank 6, and the nitrogen generator 5 are all equipped with valves to control the operation of the pipeline gas. The first filter 401 is a T-class filter with a filtration accuracy of 1μm; the second filter 402 and the fourth filter 404 are both A-class filters with a filtration accuracy of 0.01μm; the third filter 403 is an AR-class dust removal filter with a filtration accuracy of 0.01μm. A flow meter is installed on the pipeline between the adsorption dryer 3 and the nitrogen generator 5 to monitor the gas flow rate.

[0035] The implementation principle of this utility model of a dual-output air source device for instrument air and nitrogen is as follows: a dual air compressor 1 compresses air to 0.65-1.0 MPa. After the oil and water in the air are removed by an oil-water separator 2, the air enters an adsorption-type refrigerated dryer for further drying. The outlet pressure is 0.4-1.0 MPa. The dried air is divided into two paths: one path enters the instrument air storage tank 6 for storage, and the other path passes through a filter and a module nitrogen generator 5 to produce nitrogen with a purity of ≥99.5%, which is then stored in a nitrogen storage tank 7. When the main air compressor fails, the auxiliary air compressor automatically switches to work to ensure continuous operation of the equipment. The air guide shroud on the air compressor dissipates heat and reduces noise. In the event of a sudden power outage, the gas in the instrument air storage tank 6 and the nitrogen storage tank 7 can be stably output for 1-2 hours to ensure the safe operation of the downstream equipment.

[0036] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0037] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A dual-output air source device for instrument air and nitrogen generation, comprising a dual-unit air compressor (1), an oil-water separator (2), an adsorption dryer (3), a filtration system (4), a nitrogen generator (5), an instrument air storage tank (6), and a nitrogen storage tank (7), characterized in that: The dual air compressor (1) includes a first screw air compressor (101) and a second screw air compressor (102). The inlet of the oil-water separator (2) is connected to the outlet of the dual air compressor (1). The inlet of the adsorption dryer (3) is connected to the outlet of the oil-water separator (2). The filtration system (4) includes a first filter (401), a second filter (402), a third filter (403), and a fourth filter (404). The first filter (401) and the second filter (402) are located at the inlet of the adsorption dryer (3). The third filter (403) is located at the outlet of the nitrogen generator (5). The inlet of the nitrogen generator (5) is connected to the outlet of the adsorption dryer (3). The instrument air storage tank (6) is connected to the outlet of the adsorption dryer (3). A fourth filter (404) is provided between the outlet of the adsorption dryer (3), the nitrogen generator (5), and the instrument air storage tank (6). The nitrogen storage tank (7) is connected to the outlet of the nitrogen generator (5). The outlets of the instrument air storage tank (6) and the nitrogen storage tank (7) are respectively connected to the instrument air outlet (601) and the nitrogen outlet (701). Pressure gauges and safety valves are provided on both the instrument air outlet (601) and the nitrogen outlet (701). The outlet of the adsorption dryer (3) is divided into two paths, one path is connected to the instrument air storage tank (6), and the other path is connected in sequence to the filtration system (4) and the nitrogen generator (5). The outlet of the nitrogen generator (5) is connected to the nitrogen storage tank (7).

2. The instrument air nitrogen generator with dual output gas source as described in claim 1, characterized in that: The dual air compressor (1) is configured with a main and an auxiliary air compressor.

3. The instrument air nitrogen generator with dual output gas source as described in claim 1, characterized in that: An air guide shroud is installed on the air compressor.

4. The instrument air nitrogen generator with dual-output gas source as described in claim 1, characterized in that: The outlet of the adsorption dryer (3) passes through the nitrogen generator (5) to generate nitrogen gas, which enters the nitrogen storage tank (7) for use by downstream equipment.

5. The instrument air nitrogen generator with dual output gas source as described in claim 1, characterized in that: Valves are provided at the inlet of the dual air compressor (1), the instrument air storage tank (6), and the nitrogen generator (5) to control the operation of pipeline gas.

6. The instrument air nitrogen generator with dual-output gas source as described in claim 1, characterized in that: The first filter (401) is a T-class filter with a filtration accuracy of 1μm; the second filter (402) and the fourth filter (404) are both A-class filters with a filtration accuracy of 0.01μm; the third filter (403) is an AR-class dust removal filter with a filtration accuracy of 0.01μm.

7. The instrument air nitrogen generator with dual-output gas source as described in claim 1, characterized in that: A flow meter is installed on the pipeline between the adsorption dryer (3) and the nitrogen generator (5) to monitor the gas flow rate.

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