Compressor energy saving system

Abstract

The subject matter of the invention comprises an air compressor (6) powered by at least one electric motor (7) or other power generating system, an air intake valve (27) in said air compressor (6) allowing air to be taken from the external environment, an oil and air tank (8) positioned at the outlet of said air intake compressor (6) and containing compressed air and hot oil with high heat energy, compressor energy saving system (1) integrated with a compressed air generation system comprising an oil circuit (4) directly or indirectly connected to said oil and air tank (8), a thermostatic valve (19) located in said oil circuit (4) and an oil radiator (20), characterized in that; - Gas-electric circuit (2), being an installation comprising at least one air exchanger (9) connected to the oil and air tank (8) through which the hot oil with high heat energy in the oil and air tank (8) passes and through which the gas heated by said hot oil passes, pipes connected to said air exchanger (9) through which the hot gas circulates, power generation system integrated with a compressed air generation system comprising at least one turbine (10) connected to said gas-electric circuit (2) and using hot pressurized gas heated in the air exchanger (9), at least one alternator (11) which receives the rotational motion in said turbine (10) and the hot pressurized air in said turbine (11) and generates energy, -Gas-electric circuit (2), which is an installation comprising at least one air exchanger (9) connected to the oil and air tank (8) through which the hot oil with high heat energy in the oil and air tank (8) passes and through which the gas heated by said hot oil passes, pipes connected to said air exchanger (9) through which the hot gas circulates, at least one turbine (10) connected to said gas-electric circuit (2) and using pressurized hot gas heated in the air exchanger (9), the main cooling exchanger (12) reducing the pressure of the gas leaving said turbine (10), the cooling system comprising the cooling circuit (5) in which the hot gas valve (21), the gas cooling exchanger (22), the cold water pump (23), the water radiator (24) and the second cold gas pump (25) are located, which are connected to the said main cooling exchanger (12), -Oil heat exchanger (15) through which water passes, heated by high temperature oil in the oil and air tank (8), hot water circuit (3) connected to said oil heat exchanger (15) and through which water heated by said oil heat exchanger (15) passes, proportional valve (2) in said hot water circuit, a heating system comprising a hot water circuit (3) having at least one honeycomb (17) for heating purposes through which temperature-raised water passes in said hot water circuit (3), a cooling exchanger (13) through which water from said honeycombs (17) is cooled, a hot water circuit (3) having a cooling water pump (18) through which water cooled in said cooling exchanger (13) is transferred to said oil exchanger (15), Includes.

Description

[0001] COMPRESSOR ENERGY SAVING SYSTEM

[0002] Subject of Invention and Technical Field

[0003] The invention relates, in general, to an air compressor energy saving system for converting waste heat generated during operation of an air compressor into heating, cooling and electrical energy. The main characteristic feature of the invention is that the system is an air compressor energy saving system comprising a gas-electric circuit, a hot water circuit, an oil circuit and a refrigeration circuit for heating, cooling and generating electrical energy.

[0004] Known State of the Art

[0005] Today, air compressors are machines that are used to produce compressed air by compressing ambient air with standard pressure values (e.g. 1 atmosphere) at a certain rate and operate according to the principle of converting mechanical energy into pneumatic energy. The compressed air produced by an air compressor is used in many areas of industry to meet different needs. Although the working principle of air compressors, which can be summarized as converting mechanical energy into pneumatic energy, is an indispensable function for the supply of compressed air, on the other hand, the conversion of mechanical energy into heat energy rather than pneumatic energy has shown itself as a problem. Various studies have been carried out to solve the problem of lost heat, which is referred to as "waste heat" or "inert heat", in other words, to utilize waste heat for different purposes. It is possible to categorize these studies under the title of "waste heat recovery systems" in general.

[0006] In the state of the art, the most preferred approach to utilizing the waste heat generated during the operation of air compressors is systemic solutions that include one or more air compressors as the main element, together with various elements such as electronic, hydraulic and / or pneumatic devices. Examples include various systems configured to heat an environment (e.g. a room) using said waste heat.

[0007] In the international patent application numbered W02015147500A1 , which is encountered in the known state of the art, a power generation system using an organic compound instead of water as a liquid and developed with the Organic Rankine Cycle (ORC) principle to increase thermal energy efficiency is mentioned. The main feature of the invention is that the waste heat generated during the compression of the air by the compressor heats an apparatus called a super heater, and the organic fluid whose kinetic energy is increased by the said super heater rotates a turbine, thus enabling the generation of electrical energy from waste heat. It is claimed that the point where the invention differs from other systems that generate electrical energy from waste heat with the Organic Rankine Cycle (ORC) principle is that the organic fluid used has a low boiling point and high vapor pressure.

[0008] In the patent document numbered EP3499037B1, which is encountered in the known state of the art, an invention is mentioned that allows hot water to be provided at the desired temperature even when the compressor load factor is low and has the function of improving the waste heat recovery rate. The main elements of the invention are a compressor main body, an oil separator, a gas pipeline to supply compressed gas separated from the oil by the oil separator, and a heat exchanger. The invention further comprises a hot water storage tank, circulation circuits, circulation pump and a control device for stopping the circulation pump or reducing its rotational frequency

[0009] Korean patent document KR20180007452A, which is found in the known state of the art, describes a system for generating electrical energy by using the air and oil heat of a screw compressor to generate electricity. A generator - for collecting the air and oil heat of a screw compressor - is connected to a screw-type compressor and includes the following units a heat exchange unit, an expansion unit, a generation unit, a condensing unit, a pump unit, a containment unit, a heat conversion unit, a refrigerant oil inlet unit, a compressed air processing pipe and an oil processing pipe. It is claimed that the invention differs from similar systems in that it is capable of instantaneously calculating and displaying to the user the rates at which the waste heat generated during the operation of the air compressor is converted into electrical energy.

[0010] In the Chinese patent document CN103590863A, which is encountered in the known state of the art, a hybrid energy recycling system structured according to the Carnot-Organic Rankine principle developed to increase the thermal efficiency of the Organic Rankine cycle is mentioned. The invention essentially comprises an Organic Rankine cycle circuit and a Carnot cycle circuit. Said Organic Rankine cycle circuit comprises a heat regenerator, a pipeline, a working fluid pump, an evaporator, a thermodynamic power conversion machine, a condenser, a gas-liquid separator, which are connected sequentially in a circle along a pipeline. The said Carnot cycle circuit is characterized by a series of compressors and heat exchangers connected in series, with a refrigerant arranged between each two compressors. The invention based on energy efficiency, as defined in particular in claim 2 and claim 8, is claimed to differ from similar systems according to the aerodynamic and / or hydrodynamic characteristics of the fluid under study.

[0011] The patent document CN104454048A, which is encountered in the known state of the art, relates to the ORC expansion recycling method and a waste heat device equipped with an air compressor. The working method of the system described in the mentioned document starts with transferring the waste heat generated during the operation of the compressor to an insulated water tank and obtaining hot water at a value above 90 °C. This hot water flows through the pipeline to the evaporator and heats the organic working medium stored in the evaporator. As a result of this process, vapor - not water vapor - is obtained from the organic liquid. This steam is used to generate electrical energy with the help of a generator. The vapor - or exhaust gas - from the generator enters the condenser, preferably cooled by cooling water or cooling air, and the fluid is recirculated back into the water tank, where it is switched to the liquid phase by the pressure pump. It was also noted that the waste heat generated during the operation of the air compressor can be used to generate electricity as well as to directly drive rotating machinery such as fans. Utility patent document CN215566615U, which is found in the known state of the art, mentions an energy-efficient water-cooled variable frequency screw air compressor. The said compressor consists of a compressor body, an air filter tank, an air inlet pipe, a heat exchange box, an oil and gas separation tank, a generator (electricity), a steam turbine, a motor and a battery. The principle of operation of the invention is as follows; the drive shaft of the screw air compressor body is first attached to the motor and the motor can be put into use. During the use process, the screw air compressor body continuously compresses the air, and the compressed air and oil together with the cooling liquid in the heat exchange tank enter the oil and gas separation tank to cool the high temperature oil. The heat of the liquid-gas mixture boils the water in the cooling tank and discharges it through the exhaust port on the separation plate to rotate the steam turbine, thereby driving the generator to generate electricity and storing the electric energy in the battery. The cooled gas is discharged through the three-way pipe to the pneumatic components and air filter tank, while the cooled oil is returned to the screw air compressor.

[0012] The invention CN110762003A, which is encountered in the known state of the art, relates to a drying system using waste heat treatment of compressed air with a screw air compressor, comprising a generator, a condenser, an evaporator, an absorber and an interconnected screw air compressor, an oil and gas separator, and a drying system using a screw air compressor to heat treat compressed air. The generator has a generator casing pipe, a condenser casing pipe, an evaporator casing pipe and an absorber casing pipe, respectively, and is characterized in that it further comprises a compressed air drying processor and a sleeve-type heat exchanger.

[0013] The invention US8575774B2, which is known in the art, relates to a generator-steam turbine-turbo compressor assembly configured to increase energy efficiency. The invention essentially comprises a variable frequency generator, a steam turbine and a turbo compressor operable by the generator and / or the steam turbine. The invention provides a generator-steam turbine-turbo compressor array and a method for operating the same, and a system in which the generator-steam turbine-turbo compressor array has a high efficiency and low investment costs.

[0014] The invention CN208252306U, which is in the state of the art, relates to the recovery of waste heat generated during the operation of air compressors used in the automobile industry, integrated with a water storage system. The invention essentially comprises a heat pump unit, a heating circulation pump, a cold storage tank, a pipeline, an electric valve, a sensor and an automatic control system. The evaporator side of the said heat pump unit is connected to the cooling water outlet pipe of the air compressor and is returned to the cooling tower after being absorbed by the evaporator. The outlet end of the heating circulation pump is connected to the inlet end of the condenser of the heat pump unit. The outlet end of the condenser is connected to the heating water separator, resulting in a self-heating water separator divided into two branches. Here, the first branch transfers the air to the coating line air conditioning box and preheats it. The second branch flows into the main heating system main water separator and runs in parallel with the original system. The heating water collector is connected to the water return end of the heat pump together with the main water supply unit. Said coolant is connected to the outlet of the cooling tower and to the inlet of the coolant tank. The outlet of said cooling water tank is connected to the inlet of the cooling tower circulation pump. The cooling tower circulation pump outlet is connected to the centrifugal cooler condenser inlet, the heat pump unit condenser inlet is connected to the centrifugal cooler condenser outlet, and the heat pump unit condenser outlet is connected to the cooling tower inlet. It is claimed that the invention differs from similar systems with its automatic control system, which can be summarized as the heat pump unit being on the evaporator side and connecting the air compressor cooling water outlet pipe and returning it to the cooling tower after being absorbed by the evaporator, and the working method consisting of six steps that operate the system.

[0015] The present inventions exemplified above, and the like, generally appear to be systems configured to convert the waste heat generated during the operation of a compressor into electrical energy by means of a fluid and a turbine, or to heat a water source with the waste heat . Although the aforementioned inventions are useful systems in terms of energy saving, it is seen that there is a need for a system that has the functions of both generating electrical energy and heating and / or cooling by using the waste heat of the compressor. Considering that the above- mentioned inventions are systems that are formed by combining many devices and mechanical parts, it is thought that the function of generating electrical energy on the one hand and performing heating and / or cooling functions on the other hand cannot be met by combining two of the aforementioned inventions. It is very difficult to structure the invention CN208252306U or the like, the main function of which can be summarized as heating another water source with the waste heat generated during the operation of the compressor, and the invention US8575774B2 or the like, the main function of which is to convert the said waste heat into electrical energy, as a system, because each system is formed by combining many devices and mechanical parts. In a system whose main purpose is to recover the waste heat generated during the operation of the compressor by using it in heating or cooling operations, it may seem like a solution to simply add a turbine and expect the system to also generate electrical energy, but in practice, configuring the systems to be fully capable of both heating / cooling and generating electrical energy presents itself as a technical challenge to be overcome

[0016] Technical problems that the invention aims to solve

[0017] The present invention relates to an air compressor energy saving system in which waste heat is converted into electrical energy while being used in heating and cooling processes in order to solve the problems existing in the known state of the art and discussed in the previous section. The inventive system may be called an energy conversion system integrated into compressed air production systems or a compressor energy saving system. The invention relates an air compressor energy saving system comprising a gas-electric circuit, a hot water circuit, a oil circuit and a cooling circuit that allows the system to generate heating, cooling and electrical energy with the hot oil obtained in the compressor systems and the heat energy in this hot oil. The most important advantage of the invention is that the heat energy in the hot oil generated during the operation of the compressor is used to heat the gas with at least one heat exchanger, and the energy in the gas is used to rotate the turbine and feed the alternator that generates electrical energy. Thus, in the known state of the art, instead of the hot oil from the compressor being lost as idle heat, electrical energy is generated. This hot air used in the turbine is brought to the cooling heat exchanger and its pressure is reduced, allowing the previous turbine to rotate more easily. The resulting depressurized cold air is utilized as a second energy use for cooling in air conditioning installations.

[0018] Another advantage of the invention is that the hot oil can be used for heating purposes by sending it directly or partially to heating installations. In this way, both pressurized gas is obtained and the environment can be heated.

[0019] Another advantage of the invention is that the hot oil and therefore the heat energy produced in air compressors can be used simultaneously or in parts for heating, cooling and electricity generation. Depending on the need, the installation can be used only for heating the gas by the hot oil and this heated gas rotates the turbine and then generates electricity with the generator, while it can also be used for cooling purposes by reducing the pressure of the gas coming out of the turbine. With additional components to the same installation, the hot oil can also be used to heat the heating system. Therefore, the system can be used to produce energy as heating, cooling and electrical energy or to save energy all together or to prefer any desired area (heating, cooling or electricity generation).

[0020] For a better understanding of the inventive system, the following figures will be used.

[0021] Explanation of Figures

[0022] Figure-1 : The conceptual design of the energy generation or saving system with the compressor output of the invention, which includes electricity generation, heating and cooling devices together Part Reference Numbers to Help Explain the Invention

[0023] 1- Compressor energy saving system

[0024] 2- Gas-Electricity generation circuit

[0025] 3- Hot water circuit

[0026] 4- Oil circuit

[0027] 5- Cooling circuit

[0028] 6- Air compressor

[0029] 7- Electric motor

[0030] 8- Oil and air tank

[0031] 9- Air heat exchanger

[0032] 10-Turbine

[0033] 11 -Alternator

[0034] 12-Main cooling heat exchanger

[0035] 13-Cooling heat exchanger

[0036] 14-Cold gas pump

[0037] 15-Oil heat exchanger

[0038] 16-Hot water pump

[0039] 17-Heating core

[0040] 18-Cold water pump

[0041] 19-Thermostatic valve

[0042] 20-Oil radiator

[0043] 21 -Hot gas valve

[0044] 22-Gas cooling heat exchanger

[0045] 23-Cold water pump

[0046] 24- Water radiator

[0047] 25-Second cold gas pump

[0048] 26-Check valve

[0049] 27-Air intake

[0050] 28-Proportional valve Detailed Description of the Invention

[0051] The energy conversion system or compressor energy saving system integrated into the compressed air production systems subject of the invention; energy production or energy saving system that enables the use of heat energy obtained in compressor systems for electricity generation, heating and cooling purposes, basically aims to use the oil required in compressed air production and the heat energy in this oil as heating, cooling and electrical energy and thus to produce additional energy or an energy saving system in total. Figure-1 is only a conceptual design to facilitate understanding of the invention. The structure used in Figure-1 shows an installation structure in which the hot oil and thus heat energy from the compressed air production compressor is used for electrical energy generation, space heating or cooling. However, this structure can also include one or two of these three energy conversions if desired.

[0052] Invention comprises an air compressor (6) energized by at least one electric motor (7) or other power generating system, an air intake valve (27) in said air compressor (6) allowing air to be taken from the external environment, an oil and air tank (8) positioned at the outlet of said air intake compressor (6) and containing compressed air and hot oil with high heat energy, compressor energy saving system (1 ) integrated with a compressed air generation system comprising an oil circuit (4) directly or indirectly connected to said oil and air tank (8), a thermostatic valve (19) located in said oil circuit (4) and an oil radiator (20), characterized in that;

[0053] - Gas-electric circuit (2), being an installation comprising at least one air exchanger (9) connected to the oil and air tank (8) through which the hot oil with high heat energy in the oil and air tank (8) passes and through which the gas heated by said hot oil passes, pipes connected to said air exchanger (9) through which the hot gas circulates, power generation system integrated with a compressed air generation system comprising at least one turbine (10) connected to said gas-electric circuit (2) and using hot pressurized gas heated in an air exchanger (9) , at least one alternator (11 ) which receives rotational motion in said turbine (10) with hot pressurized air and in the turbine and generates energy, - Gas-electric circuit (2), being an installation comprising at least one air exchanger (9) connected to the oil and air tank (8) through which the hot oil with high heat energy in the oil and air tank (8) passes and through which the gas heated by said hot oil passes, pipes connected to said air exchanger (9) through which the hot gas circulates, at least one turbine (10) connected to said gas-electric circuit (2) and using pressurized hot gas heated in the air exchanger (9), the main cooling exchanger 12) reducing the pressure of the gas leaving said turbine (10), the cooling system comprising the cooling circuit (5) in which the hot gas valve (21 ), the gas cooling exchanger (22), the cold water pump (23), the water radiator (24) and the second cold gas pump (25) are located, which are connected to the said main cooling exchanger (12),

[0054] - Oil heat exchanger (15) through which water passes, heated by high temperature oil in the oil and air tank (8), hot water circuit (3) connected to said oil heat exchanger (15) and through which water heated by said oil heat exchanger (15) passes, proportional valve (2) in said hot water circuit, a heating system comprising a hot water circuit (3) having at least one honeycomb (17) for heating purposes through which temperature-raised water passes in said hot water circuit (3), a cooling exchanger (13) through which water from said honeycombs (17) is cooled, a hot water circuit (3) having a cooling water pump (18) through which water cooled in said cooling exchanger (13) is transferred to said oil exchanger (15),

[0055] It is a system that includes.

[0056] As mentioned above, the energy conversion system integrated into the compressed air production systems or the energy saving system with compressor may include all of the electricity generation system, cooling system or heating system as well as at least one of them. Depending on the environment in which the compressor is used, it can generate electricity only, heat only for the heating system or be used for the cooling system. It can even be a dual use with at least one of them. In the energy conversion system integrated into the compressed air production systems or compressor energy saving system in the electricity generation system; the oil in the oil and air tank (8) is heated in the compressor system and has a high temperature. By passing the hot oil with high heat energy in the oil and air tank (8) through the air exchanger (9), which is a heat transfer medium, the high temperature oil transfers most of its energy to the air in the gas-electric circuit (2). The air in the gas-electric circuit (2) is now at high temperature and pressure. If this pressure is transferred to a gas turbine (10) in the gas-electric circuit (2), the turbine (10) will rotate and transfer its energy to the alternator (11 ) connected to it. Electric energy will thus be generated. After the turbine (10), a main cooling exchanger (12) and / or a cooling exchanger (13) is positioned in the gas-electric circuit (2) in order to further reduce the pressure and cool the air leaving the turbine (10), which is depressurized. The cooling exchanger (13) may be located both in the gas-electric circuit (2) and in the hot water circuit (3) or only in the hot water circuit (3). The air in the cooling exchanger (12) is cooled and depressurized, which will also create a vacuum effect at the outlet of the turbine (10) and increase the turbine efficiency. The cooled gas will then be sent to the air exchanger (9) to be recycled by the cold gas pump (14).

[0057] If some or all of the hot oil in the oil and air tank (8) is desired to be used in the cooling system in the energy conversion system or compressor energy saving system integrated into the compressed air production systems of the invention, this time, the gas-exchanger (9) is connected to the aforementioned air exchanger (9) and is an installation containing pipes through which the hot gas circulates. hot gas valve (21 ) and gas cooling exchanger (22) in connection with the main cooling exchanger (12), which reduces the pressure of the gas exiting at least one turbine (10) in the electrical circuit (2) using heated pressurized hot gas, is a system comprising a cold water pump (23), a water radiator (24) and a cooling circuit (5) where the second cold gas pump (25) is located. Here the chilled gas will be used as cooling in the system.

[0058] In the energy conversion system or compressor energy saving system integrated into the compressed air production systems of the invention, if some or all of the hot oil in the oil and air tank (8) is desired to be used in the cooling system, there is an oil heat exchanger (15) through which water passes, which is heated by high temperature oil. Water passes through the oil heat exchanger (15) and heats the water. This is the classic water heating system. In the hot water circuit (3) through which the water heated by the oil heat exchanger (15) passes, there is a proportional valve (2) and then there are honeycombs (17) for heating. Since hot water passes through the honeycombs, it heats the environment. The system includes a cooling heat exchanger (13) where the water taken from the honeycombs (17) is cooled, and a cooling water pump (18) where the water cooled in the said cooling heat exchanger (13) is transferred to the said oil heat exchanger (15).

[0059] Application of the Invention to Industry

[0060] The energy conversion system or compressor energy saving system integrated into the compressed air production systems of the invention can be integrated into a high-pressure air compressor system for electricity generation, heat generation or cooling. In this way, it can be applied in industrial plants, laboratories and wherever compressed air production is required. The system can be produced as a package if desired. In other words, when a compressor is produced, these components can be added together and put on the market not as a plant but as a machine.

Claims

CLAIMS1 - The invention provides an air compressor (6) powered by at least one electric motor (7) or other power generating system, an air intake valve (27) in said air compressor (6) allowing air to be taken from the external environment, an oil and air tank (8) positioned at the outlet of said air intake compressor (6) and containing compressed air and hot oil with high heat energy, compressor energy saving system (1 ) integrated with a compressed air generation system comprising an oil circuit (4) directly or indirectly connected to said oil and air tank (8), a thermostatic valve (19) located in said oil circuit (4) and an oil radiator (20), characterized in that;- Gas-electric circuit (2), being an installation comprising at least one air exchanger (9) connected to the oil and air tank (8) through which the hot oil with high heat energy in the oil and air tank (8) passes and through which the gas heated by said hot oil passes, pipes connected to said air exchanger (9) through which the hot gas circulates, power generation system integrated with a compressed air generation system comprising at least one turbine (10) connected to said gaselectric circuit (2) and using hot pressurized gas heated in the air exchanger (9), at least one alternator (11 ) which receives the rotational motion in said turbine (10) and the hot pressurized air in said turbine (11 ) and generates energy,-Gas-electric circuit (2), being an installation comprising at least one air exchanger (9) connected to the oil and air tank (8) through which the hot oil with high heat energy in the oil and air tank (8) passes and through which the gas heated by said hot oil passes, pipes connected to said air exchanger (9) through which the hot gas circulates, at least one turbine (10) connected to said gas-electric circuit (2) and using pressurized hot gas heated in the air exchanger (9), the main cooling exchanger (12) reducing the pressure of the gas leaving said turbine (10), the cooling system comprising the cooling circuit (5) in which the hot gas valve (21 ), the gas cooling exchanger (22), the cold water pump (23), the water radiator (24) and the second cold gas pump (25)are located, which are connected to the said main cooling exchanger (12),-Oil heat exchanger (15) through which water passes, heated by high temperature oil in the oil and air tank (8), hot water circuit (3) connected to said oil heat exchanger (15) and through which water heated by said oil heat exchanger (15) passes, proportional valve (2) in said hot water circuit, a heating system comprising a hot water circuit (3) having at least one honeycomb (17) for heating purposes through which temperature-raised water passes in said hot water circuit (3), a cooling exchanger (13) through which water from said honeycombs (17) is cooled, a hot water circuit (3) having a cooling water pump (18) through which water cooled in said cooling exchanger (13) is transferred to said oil exchanger (15),Includes.

2. The compressor energy saving system (1 ) integrated with a compressed air generation system of claim 1 , characterized in that it may comprise all or at least one of a power generation system, a refrigeration system or a heating system.