Gas compression power reduction system and method

Abstract

The present disclosure provides a gas compression plant connectable to an electric grid and a gas production unit. The plant comprises an inlet, an outlet, a main compressor, an electric drive module, and an recycle line. A power reduction unit is connected in parallel to the recycle line and includes an auxiliary compressor and a high-pressure storage vessel. A control system activates and deactivates the power reduction unit. When activated, the auxiliary compressor removes gas from the recycle line while the main compressor operates at a defined speed, reducing gas pressure. The removed gas is stored in the high-pressure storage vessel. When deactivated, the power reduction unit refills the main compression line with stored gas before resuming normal operation of the main compressor.

Description

Gas Compression Power Reduction System and MethodDescriptionTECHNICAL FIELD

[0001] The present disclosure concerns a gas compression power reduction system, particularly intended for Hydrogen, and operating method thereof.BACKGROUND ART

[0002] Gas compression plants play an important role in various industrial applications, including, and particularly, the production and distribution of Hydrogen. These plants or systems are designed to increase the pressure of gases, allowing for efficient storage, transportation, and utilization.

[0003] Also, in recent years, there has been a growing interest in green Hydrogen production, which relies on renewable energy sources such as solar and wind power to generate Hydrogen through electrolysis.

[0004] Conventional gas compression plants typically operate continuously, consuming a significant amount of power to maintain the desired pressure levels. However, the intermittent nature of renewable energy sources presents challenges for maintaining consistent operation of these systems. During periods of low or no power generation, such as nighttime for solar-powered plants, compression systems must either be shut down completely or operate in an idle mode, that corresponds to an off line condition, in which the process gas is circulated by the compressor through the recycle loop. Such operating condition, being isolated from the main process circuit, permits to reduce the compressor rotating speed, thus reducing absorbed power.

[0005] One of the primary technical problems associated with idle mode of gas compression systems is the high power consumption required to maintain the system running at a predefined speed. This power demand can quickly deplete energy storage systems, such as battery storage, which are often used to bridge gaps in renewable energy production. Additionally, frequent cycling between full operation and idle modes can lead to increased wear on compressor components, potentially reducing the overall lifespan of the equipment.

[0006] Another significant technical problem in gas compression systems, particularly those handling Hydrogen, is the phenomenon of Hydrogen embrittlement. This process can cause structural degradation of metallic components, especially when subjected to repeated stress cycles. The need to frequently adjust compressor speeds and impeller stress levels during transitions between normal and idle modes can worsen this issue, potentially compromising the reliability and operating life of the system.

[0007] Furthermore, the sizing of battery storage systems for renewable energy -powered compression plants presents a practical limitation. Larger battery systems can provide extended operation during periods of low energy production but come with increased costs, space requirements, and maintenance needs. Balancing the size of energy storage with the operational requirements of the compression system remains a significant problem in plant design and operation.

[0008] It has been appreciated that a gas compression power reduction system is needed that overcomes the above mentioned technical problems.SUMMARY

[0009] In another aspect, disclosed herein is a gas compression plant connectable to an electric grid and a gas production unit. The plant comprises an inlet connected to the gas production unit for receiving gas to be compressed, an outlet from which compressed hydrogen is collected, and a main compressor for compressing the gas from the gas production unit. An electric drive module connected to the electric grid drives the main compressor, and a recycle line connects the inlet and outlet. A power reduction unit, connected in parallel to the recycle line, includes an auxiliary compressor that removes gas from the recycle line while the main compressor continues operating at a defined speed, thus reducing the gas pressure from the main compressor. A high- pressure storage vessel stores the gas removed by the auxiliary compressor and releases it when necessary. A control system activates and deactivates the power reduction unit, enabling the auxiliary compressor to fill the high-pressure storage vessel and later refill the main compression line with the stored gas before resuming normal operation of the main compressor.

[0010] A further aspect of the present disclosure is drawn to a gas compression plant wherein the main compressor operates in idle mode when the power generated by theelectric grid falls below a certain threshold. The control system is configured to activate the power reduction system at the start of the idle mode.

[0011] In another aspect, the subject matter disclosed herein concerns a gas compression plant, wherein the control system comprises a recycle valve between the inlet and the main compression outlet, an input valve between the inlet and the main compressor, and an output valve between the main compressor and the outlet. The plant further comprises an extraction valve, allowing the auxiliary compressor to take gas from the main compression line and store it in the high-pressure storage vessel when the power reduction unit is activated, as well as an introduction valve to allow the stored gas to be reintroduced into the main compression line.

[0012] A further aspect of the present disclosure is drawn to a gas compression plant featuring a control logic unit configured to control and coordinate the control system. The power reduction unit comprises an electric motor to drive the auxiliary compressor.

[0013] In another aspect, disclosed herein is a gas compression plant where the electric drive module comprises an electric motor to convert electric energy from the electric grid into mechanical energy for driving the main compressor. A variable speed drive system controls the energy flow from the electric grid. Additionally, a cooler is provided between the main compressor and the outlet to cool the compressed gas. The electric grid can include power generated from renewable sources, such as wind turbines or solar panels.

[0014] A further aspect of the present disclosure is drawn to a method for reducing power consumption in a gas compression plant during idle mode. The method involves activating a control system to engage the power reduction unit, which directs the auxiliary compressor to fill the high-pressure storage vessel with gas from the main compression line. The control system then deactivates the power reduction unit, refilling the main compression line with stored gas before resuming normal operation of the main compressor.

[0015] In another aspect, disclosed herein is a method in which the activation step involves closing the input and output valves, opening the recycle valve and extractionvalve, and activating the auxiliary compressor to compress gas from the mam compression line and store it in the high-pressure storage vessel, all while reducing the speed of the main compressor. During the deactivation step, the recycle and extraction valves are closed, the introduction valve is opened, and the gas stored in the high- pressure storage vessel is reintroduced into the main compression line, followed by an increase in the operating speed of the main compressor.

[0016] A further aspect of the present disclosure is drawn to a method for operating the gas compression plant in compression mode, including the steps of opening the input and output valves and closing the introduction valve. The power reduction unit is activated when there are fluctuations in the electric flow from the electric grid.BRIEF DESCRIPTION OF THE DRAWINGS

[0017] A more complete appreciation of the disclosed embodiments of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:Fig. 1 illustrates a block diagram of a gas compression plant, according to aspects of the present disclosure;Fig. 2 illustrates a flowchart for a method of operating a gas compression plant, according to an embodiment;Fig. 3 illustrates a detailed flowchart for activating a power reduction unit in a gas compression plant;Fig. 4 illustrates a flowchart for deactivating a power reduction unit in a gas compression plant; andFig. 5 illustrates a flowchart for operating a gas compression plant in normal compression mode.

[0018] Common reference numerals are used throughout the figures to indicate similar features.DETAILED DESCRIPTION OF EMBODIMENTS

[0019] According to one aspect, the present subject matter is directed to a gas compression plant aimed at optimizing the power consumption during idle mode. It connects to an electric grid and gas production unit. The gas, mainly Hydrogen, is compressed by a main compressor, arranged on a recycle line.

[0020] A power reduction unit, connected in parallel to the recycle line, includes an auxiliary compressor and a high-pressure storage vessel. This unit removes Hydrogen from the recycle line while the main compressor operates at a defined speed, reducing Hydrogen pressure. The removed Hydrogen is stored in the high-pressure storage vessel. A control system activates and deactivates the power reduction unit. When activated, the auxiliary compressor fills the storage vessel with gas from the main line. When deactivated, it refills the main line before normal operation resumes. This may reduce power consumption during low power periods while maintaining the main compressor speed, potentially reducing component stress and extending operational life.

[0021] Referring to Fig. 1, a gas compression plant 1 is shown, which is connectable to an electric grid 2 and a gas production unit 3. The gas compression plant 1 comprises an inlet 11, which is connected to the gas production unit 3. The inlet 11 receives the gas to be compressed. The gas compression plant 1 also includes an outlet 12, from which the compressed gas is collected. Any additional plant or part of it that uses the compressed Hydrogen or compressed gas, in general can be connected to the outlet 12.

[0022] The gas compression plant 1 comprises a main compressor 13, connected to the inlet 11, from which the gas, in particular, referring to the embodiment described, the Hydrogen, derives, coming from the Hydrogen production unit 3. The main compressor 13 can be of different kinds. In general, the main compressor 13 can be of rotating type.

[0023] The inlet 11, the outlet 12, and the main compressor 13 together form the main compression line 14.

[0024] The gas compression plant 1 comprises also an electric drive module 16. The electric drive module 16 is connected to the electric grid 2 and drives the main compressor 13. The electric drive module 16 may include an electric motor 161 and a variable speed drive system 162. The electric motor 161 transforms the electric energy from the electric grid 2 into mechanical energy for driving the main compressor 13.The vanable speed drive system 162 controls the now of energy from the electric gnd 2 to the electric motor 161. This allows the speed of the main compressor 13 to be adjusted based on the available power from the electric grid 2.

[0025] Still referring to Fig. 1, the gas compression plant 1 may also comprise a cooler 17. In some cases, the cooler 17 is connected between the main compressor 13 and the outlet 12. The cooler 17 is adapted to cool the Hydrogen that has been compressed by the main compressor 13. This can help to maintain the temperature of the compressed Hydrogen within a desired range, which may be beneficial for the operation of the gas compression plant 1

[0026] Referring to Fig. 1, the electric grid 2 of the gas compression plant 1 may comprise electric generating machines such as a wind turbine plant 21 and / or a solar panel plant 22. These renewable energy sources may provide the electric power necessary to drive the main compressor 13 and the auxiliary compressor 41. The use of renewable energy sources has often the problem to be variable and fluctuate, depending on the weather conditions.

[0027] Continuing referring to Fig. 1, the gas compression plant 1 further comprises a power reduction unit 4. The power reduction unit 4 is connected in parallel to the recycle line 15. The power reduction unit 4 comprises an auxiliary compressor 41 and a high-pressure storage vessel 42.

[0028] The auxiliary compressor 41 is adapted to remove the gas, or the Hydrogen, in particular, from the recycle line 15 while the main gas compressor 13 continues operating at a defined speed. This operation reduces the gas pressure in the main compressor 13, thereby reducing the power consumption of the gas compression plant 1 during idle operation, as better explained below.

[0029] The auxiliary compressor 41 can be, also, of a rotative type, although other type of compressors can be installed in the plant 1.

[0030] The high-pressure storage vessel 42 is configured to store the Hydrogen extracted by the main circuit and compressed by the auxiliary compressor 41. The gas stored in the high-pressure storage vessel 42 is re-introduced in the main line 14 when. the main compressor 13 is put back in line with the plant, i.e., when the mam compressor 13 is reactivated to generate energy. The pressure at which the Hydrogen is stored in the high-pressure storage vessel 42 must be greater than 1 bar absolute, till a predetermined value that is set by the system design.

[0031] In some aspect, the power reduction unit 4 operates in conjunction with the control system 5. The control system 5 is configured to activate and deactivate the power reduction unit 4 based on the operating conditions of the gas compression plant 1. When the power reduction unit 4 is activated, the auxiliary compressor 41 removes Hydrogen from the recycle line 15 and stores it in the high-pressure storage vessel 42. This operation reduces the gas pressure in the main compressor 13 and the power consumption of the gas compression plant 1.

[0032] When the power reduction unit 4 is deactivated, the high-pressure storage vessel 42 releases the stored Hydrogen or gas in general, back into the main compression line 14. This operation increases the gas pressure in the main compressor 13 and prepares the gas compression plant 1 for normal operation.

[0033] A control system 5 coordinates the operation of the power reduction unit 4 and, consequently, of the main compressor 13, to optimize the power consumption of the gas compression plant 1 during idle mode.

[0034] The control system 5 actually controls the operation of power reduction unit 4. In some aspect, the control system 5 is configured to activate and deactivate the power reduction unit 4 based on the operating conditions of the gas compression plant 1.

[0035] When the power reduction unit 4 is activated by the control system 5, the auxiliary compressor 41 removes gas from the recycle line 15 and stores it in the high- pressure storage vessel 42. This operation reduces the gas pressure in the main compressor 13, thereby reducing the power consumption of the gas compression plant 1 during idle mode.

[0036] The main compressor 13 may operate in an idle mode when the power generated by the electric grid 2 is below a certain threshold. This happens quite frequently when the electric grid 2 connected to the gas compression plant 1 comprises renewable electric generating machines such as a wind turbine plant 21 and / or a solar panel plant22, which, as mentioned, have a fluctuating electric generation. In these cases, the control system 5 is configured to activate the power reduction system at the beginning of the idle mode of the main compressor 13. This operation allows the main compressor 13 to continue operating at a reduced power level during idle mode, while maintaining a sufficient gas pressure in the main compression line 14.

[0037] Continuing referring to Fig. 1, the control system 5 of the gas compression plant 1 comprises several valves that regulate the flow of gas through the system. In some embodiments, the control system 5 comprises an recycle valve 51. The recycle valve 51 is connected between the inlet 11 and the outlet 12. The recycle valve 51 is adapted to control the flow of gas in the recycle line 15, which, as mentioned, connects the inlet 11 and the outlet 12.

[0038] The control system 5 also comprises an input valve 52 and an output valve 53. The input valve 52 is connected between the inlet 11 and the main compressor 13. This valve is used to control the flow of gas from the inlet 11 to the main compressor 13. The output valve 53 is connected between the main compressor 13 and the outlet 12. This valve is used to control the flow of compressed gas from the main compressor 13 to the outlet 12.

[0039] In addition to the valves in the control system 5, the gas compression plant 1 also comprises an extraction valve 54 and an introduction valve 55, which are associated with the power reduction unit 4. The extraction valve 54 is connected between the outlet 12 and the auxiliary compressor 41. When the power reduction unit 4 is activated, the extraction valve 54 may be opened to allow the auxiliary compressor 41 to take the gas from the main compression line 14. The gas is then stored in the high- pressure storage vessel 42.

[0040] The introduction valve 55 is connected between the high-pressure storage vessel 42 and the inlet 11. When the power reduction unit 4 is deactivated, the introduction valve 55 may be opened to allow the high-pressure storage vessel 42 to release the stored gas back into the main compression line 14. This operation increases the gas pressure in the main compressor 13 and prepares the gas compression plant 1 for normal operation.

[0041] In this way, the control system 5, in conjunction with the extraction valve 54and the introduction valve 55, coordinates the operation of the power reduction unit 4 and the main compressor 13 to optimize the power consumption of the gas compression plant 1 during idle mode.

[0042] The gas compression plant 1 may also comprise a control logic unit U. The control logic unit U is configured to control and coordinate the control system 5. This may allow for efficient management of the various components of the gas compression plant 1, including the main compressor 13, the power reduction unit 4, and the various valves associated with the control system 5.

[0043] The control logic unit U may be implemented in various ways, each offering different advantages.

[0044] In some embodiments, the control logic unit U may be implemented using a dedicated programmable microprocessor. This solution may offer high processing speed and flexibility in programming. The microprocessor can be customized with specific firmware to handle the complex control algorithms required for managing the gas compression plant. A microprocessor-based implementation may provide high processing speed for real-time control, compact size suitable for integration within existing control panels, and low power consumption. It may also offer the ability to handle complex calculations and algorithms, as well as the potential for easy firmware updates to improve functionality.

[0045] In some other embodiments, the control logic unit U may be implemented using a Programmable Logic Controller (PLC). PLCs are robust industrial control systems designed specifically for automation tasks. A PLC-based implementation may offer high reliability and durability in industrial environments, along with built-in in- put / output capabilities for direct connection to sensors and actuators. PLCs typically feature a modular design allowing for easy expansion and modification, and provide a familiar programming environment for industrial control engineers. They may also offer extensive diagnostic capabilities for troubleshooting.

[0046] The control logic unit U may also be implemented using a general-purpose computer, such as an industrial PC. This solution may offer high computational power and flexibility. A general-purpose computer implementation may provide high processing power for handling complex control algorithms and data analysis, as well asthe ability to run advanced software packages for optimization and predictive maintenance. It may allow for easy integration with existing IT infrastructure and databases, flexible human-machine interface options including touchscreens and remote access, and the capability to handle multiple tasks simultaneously, such as control, data logging, and communication.

[0047] In some other embodiments, the control logic unit U may be an FPGA. FPGAs offer the ability to implement custom digital circuits in hardware. An FPGA-based implementation may provide very fast processing for time-critical operations and the ability to implement parallel processing for complex control algorithms. It may offer low latency for real-time control applications, flexibility to reconfigure hardware functionality without changing physical components, and the potential for lower power consumption compared to general -purpose processors.

[0048] The power reduction unit 4 of the gas compression plant 1 comprises an electric motor 43 to drive the auxiliary compressor 41. This can provide a source of power for the auxiliary compressor 41, allowing it to operate independently of the main compressor 13. This may be particularly useful during periods of idle mode, when the main compressor 13 is operating at a reduced speed and the auxiliary compressor 41 is removing gas from the recycle line 15.

[0049] In some embodiments, the main compressor 13 is maintained at a defined speed while the power reduction unit 4 is activated. The defined speed may be within 10% of its nominal operating speed. This operation allows the main compressor 13 to continue compressing gas at a reduced power level during idle mode, while maintaining a sufficient gas pressure in the main compression line 14. This may reduce power consumption during low power periods while maintaining the main compressor speed.

[0050] As mentioned, the power reduction unit 4 is activated when the electric flow of the electric grid 2 fluctuates. This may occur, for example, when the power generated by the wind turbine plant 21 or the solar panel plant 22 is below a certain threshold. The control system 5 may be configured to activate the power reduction unit 4 at the beginning of an idle mode of the main compressor 13. This operation allows the main compressor 13 to continue operating at a reduced power level during idle mode, while maintaining a sufficient gas pressure in the main compression line 14. This mayreduce power consumption during low power periods while maintaining the mam compressor speed.

[0051] Referring to Fig. 2, a method 100 for reducing power consumption in the gas compression plant 1 during idle mode is illustrated.

[0052] The method 100 comprises several steps and sub-steps. In particular, the method 100 involves the step of activating 110 the control system 5 to be set to a first configuration, to activate the power reduction unit 4. This activation step 110, in said first configuration, causes the auxiliary compressor 41 to fill the high-pressure storage vessel 42 with gas (the Hydrogen) from the main compression line 14.

[0053] Also, the method 100 comprises the deactivation step 120. The deactivation step 120 involves deactivating the control system 5, to bring it in a second configuration, which in turn causes the power reduction unit 4 to refill the main compression line 14 with Hydrogen previously stored into the high-pressure storage vessel 42 in the activation step 110 before resuming normal operation of the main gas compressor 13.

[0054] Finally, the method 100 comprises the step of operating 130 the compression plant 1 in compression mode, namely bypassing the power reduction unit 4 and allowing the main compressor 13 to operate and compress the Hydrogen coming from the gas production unit 3. In this case, the control system 5 assumes a third configuration.

[0055] In some aspects of the present disclosure, the activation step 110 of the method 100 comprises sub-steps. Specifically, referring to Fig. 3, the activation step 110 may involve the step of closing 111 the input valve 52 and the output valve 53, to prevent the Hydrogen from entering or leaving the main compression line 14 during the activation process.

[0056] The activation step 110 also comprises opening the recycle valve 51 (sub-step 112). This step allows the Hydrogen (or the gas in general) to flow from the main compression line 14 to the recycle line 15, i.e. to be deviated to the power reduction unit 4.

[0057] The activation step 110 may further comprise the sub-steps of opening 113 the extraction valve 54 and closing 114 the introduction valve 55. These sub-steps allow the auxiliary compressor 41 to remove the Hydrogen (or the gas in general) from therecycle line 15 and transfer it to the high-pressure storage vessel 42 through the auxiliary compressor 41. By closing the extraction valve 55, the Hydrogen is prevented to flow away from the high-pressure storage vessel 42.

[0058] In this way, the method 100 allows for the reduction of power consumption in the gas compression plant 1 during idle mode. By activating the control system 5 and coordinating the operation of the various valves in a specific sequence, the method 100 reduces the gas pressure in the main compressor 13 while it continues to operate at a defined speed. This operation reduces the power consumption of the gas compression plant 1 during idle mode.

[0059] Also, along with the above activation of the valves, the activation step 110 of the method 110 may further involve activating 115 the auxiliary compressor 41 to compress gas originating from the main compression line 14. The compressed gas is then introduced (sub-step 116) into the high-pressure storage vessel 42. Also, the operating speed of the main compressor 13 is reduced (sub-step 125) to optimize the system's overall efficiency.

[0060] In some aspects, the deactivation step 120 of the method 100 comprises the sub-steps (see Fig. 4) of closing 121 the recycle valve 51, to prevent Hydrogen from flowing from the main compression line 14 to the recycle line 15 during the deactivation step 120.

[0061] Also, the deactivation step 120 comprises the sub-steps of closing 122 the extraction valve 54, to reduce the operation of the auxiliary compressor 41, and opening the introduction valve 55, which is directly connected to the high-pressure storage vessel 42. In this way, the high-pressure storage vessel 42 can release the stored Hydrogen back into the main compression line 14. This operation increases the gas pressure in the main compressor 13 and prepares the gas compression plant 1 for normal operation.

[0062] Then the deactivation step 120 further comprises the sub-steps of introducing 12 into the main compression line 14 the gas stored into the high-pressure storage vessel 42, allowing, at the same time the increasing 125 the operating speed of the main compressor 13, which gradually come back to it original operating speed.

[0063] In addition to the deactivation step 120, as mentioned above and as shown inFig. 2, the method 100 also comprises a further step of operating the compression plant 1 in compression mode (step 130). This operation mode allows the main compressor 13 to compress the Hydrogen coming from the gas production unit 3 at a normal operating speed. This may be particularly useful when the power generated by the electric grid 2 is above a certain threshold that may vary depending by specific plant or system conditions, typically 70% of nominal power.

[0064] In this way, the method 100 allows for the reduction of power consumption in the gas compression plant 1 during idle mode. By deactivating the control system 5 and manipulating the various valves in a specific sequence, the method 100 can increase the gas pressure in the main compressor 13 while it resumes normal operation. This operation increases the efficiency of the gas compression plant 1 during normal operation.

[0065] Referring to Fig. 5, the compression mode operating step 130 of the method 100 comprises the sub-steps of opening 131 the input valve 52 and the output valve 53. This action allows gas to flow from the inlet 11 to the main compressor 13 and from the main compressor 13 to the outlet 12. This operation prepares the gas compression plant 1 for normal operation, where the main compressor 13 compresses the gas coming from the gas production unit 3 at a normal operating speed.

[0066] In some cases, the compression mode operating step 130 also comprises closing the recycle valve 51. This step prevents gas from flowing from the main compression line 14 to the recycle line 15. Also, this step ensures that the Hydrogen in the main compression line 14 is directed towards the main compressor 13 for its compression, thereby maximizing the efficiency of the gas compression plant 1 during normal operation.

[0067] The compression mode operating step 130 may further comprise the sub-step of closing 133 the introduction valve 55. This sub-step prevents the high-pressure storage vessel 42 from releasing the stored Hydrogen back into the main compression line 14.

[0068] In this way, the method 100 allows for the efficient transition of the gas compression plant 1 from a power reduction mode to normal compression operation. By operating, the various valves (electro-valves) in a specific sequence, the method 100can optimize the operation of the gas compression plant 1.

[0069] In some embodiments, the electric drive module 16 of the gas compression plant 1 may include a battery accumulation system. This system is designed to drive the main compressor 13 and, possibly, also the auxiliary compressor 41.

[0070] In some aspect, the power reduction unit 4 is capable of reducing the inlet pressure of the second section of the main compressor 13 to approximately 1 bar-a. This reduction in inlet pressure can lead to a significant reduction in the absorbed gas power, thereby reducing the overall power consumption of the gas compression plant 1. For example a reduction in the inlet pressure to 1 bar-absolute - in a specific example - can imply a reduction in overall compression absorbed power by an amount a 27%.

[0071] In some cases, the power reduction unit 4 is capable of reducing the inlet pressure to sub-atmospheric levels. This further reduction in inlet pressure can lead to additional power savings, with benefits on the life of the impeller (not shown in the figures) in the main compressor 13. The ability to reduce the inlet pressure to sub-atmospheric levels provides the gas compression plant 1 with additional flexibility in managing its power consumption during periods of low power availability. The only drawback can be the possible risk of air entering into the process plant, and therefore it is not the common practice.

[0072] The power reduction capabilities of the power reduction unit 4 can also be compared to the reduction achievable by a speed decrease of the main compressor 13. For example, a 27% overall power reduction corresponds to the reduction achievable by a speed decrease of 10% approximately. This comparison illustrates the effectiveness of the power reduction unit 4 in reducing power consumption during idle mode. By reducing the inlet pressure instead of the speed of the main compressor 13, the power reduction unit 4 can achieve similar power savings while potentially reducing the mechanical stress cycling on the components of the main compressor 13.

[0073] In this way, the gas compression plant 1 can optimize its power consumption during idle mode, reducing the need for large battery storage systems and extending the operational life of its components. The power reduction unit 4, in conjunction with the control system 5 and the electric drive module 16, provides a reliable and efficient solution for managing power consumption in the gas compression plant 1.

[0074] In some aspect, the method 100 for reducing power consumption in the gas compression plant 1 during idle mode comprises limiting the daily rotating speed cycles range to 67% instead of 60% as currently planned. This reduction in daily cycles range can lead to the same energy consumption of reducing the speed to 60% without pressure reduction.

[0075] In some cases, the reduction in daily cycles range can also have beneficial impacts on the life of the impeller in the main compressor 13. By reducing the daily speed cycles, the main compressor 13 reduces the mechanical stress on the impeller and extending its operational life. This can lead to increased reliability and efficiency of the gas compression plant 1, further enhancing its performance.

[0076] In this way, the method 100 allows for the efficient management of power consumption in the gas compression plant 1 during idle mode. By reducing the daily cycles range, the method 100 can optimize the operation of the gas compression plant 1, potentially reducing component stress and extending operational life.ADVANTAGES

[0077] One advantage of the present disclosure is that it provides a gas compression plant with reduced power consumption during idle mode.

[0078] Another advantage of the present disclosure is that it enables efficient management of intermittent power supply typical of renewable energy sources. The power reduction unit can be activated when power from the electric grid fluctuates, allowing the gas compression machinery train to continue running during periods of low power availability thus avoiding negative effects on components life of frequent starts and stops cycles. This improves the overall reliability and sustainability of the system, particularly when integrated with renewable energy sources like wind and solar power.

[0079] It is also an advantage of the present disclosure that it may extend the operational life of compressor components. By maintaining the main compressor at a defined speed close to its nominal operating speed during idle mode, the system reduces mechanical stress on components that can occur from frequent speed changes. This potentially leads to improved reliability and reduced maintenance requirements over time.

[0080] Another advantage of the present disclosure is that it provides flexibility inmanaging power consumption. The system allows for adjustable inlet pressure reduction, including the capability to reduce pressure to sub-atmospheric levels. This flexibility enables further power savings and optimization of the compression process based on specific operational requirements.

[0081] It is also an advantage of the present disclosure that it may reduce the required size of battery storage systems in plants powered by renewable energy. By efficiently managing power consumption during periods of low energy production, the system potentially allows for smaller, more cost-effective battery systems while maintaining operational capability.

[0082] The order of the steps of the methods described herein is exemplary, but the steps may be carried out in any suitable order, or simultaneously where appropriate. Additionally, steps may be added or substituted in, or individual steps may be deleted from any of the methods without departing from the scope of the subject matter described herein.

[0083] Aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples without losing the effect sought.

[0084] While aspects of the invention have been described in terms of various specific embodiments, it will be apparent to those of ordinary skill in the art that many modifications, changes, and omissions are possible without departing form the spirt and scope of the claims. In addition, unless specified otherwise herein, the order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments.

[0085] Reference has been made in detail to embodiments of the disclosure, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the disclosure, not limitation of the disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure. Reference throughout the specification to "one embodiment" or "an embodiment" or “some embodiments” means that the particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodimentof the subject matter disclosed. Thus, the appearance of the phrase "in one embodiment" or "in an embodiment" or "in some embodiments" in various places throughout the specification is not necessarily referring to the same embodiment(s). Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.

[0086] When elements of various embodiments are introduced, the articles “a”, “an”, “the”, and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0087] The subject matter described herein can be implemented in digital electronic circuitry, or in computer software, firmware, or hardware, including the structural means disclosed in this specification and structural equivalents thereof, or in combinations of them. The subject matter described herein can be implemented as one or more computer program products, such as one or more computer programs tangibly embodied in an information carrier (e.g., in a machine-readable storage device), or embodied in a propagated signal, for execution by, or to control the operation of, data processing apparatus (e.g., a programmable processor, a computer, or multiple computers). A computer program (also known as a program, software, software application, or code) can be written in any form of programming language, including compiled or interpreted languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. A computer program does not necessarily correspond to a file. A program can be stored in a portion of a file that holds other programs or data, in a single file dedicated to the program in question, or in multiple coordinated files (e.g., files that store one or more modules, sub-programs, or portions of code). A computer program can be deployed to be executed on one computer or on multiple computers at one site or distributed across multiple sites and interconnected by a communication network.

[0088] The processes and logic flows described in this specification, including the method steps of the subject matter described herein, can be performed by one or more programmable processors executing one or more computer programs to perform functions of the subject matter described herein by operating on input data and generatingoutput. The processes and logic flows can also be performed by, and apparatus of the subject matter described herein can be implemented as, special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit).

[0089] Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read-only memory, or a random access memory, or both. The essential elements of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto-optical disks, or optical disks. Information carriers suitable for embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, (e.g., EPROM, EEPROM, and flash memory devices); magnetic disks, (e.g., internal hard disks or removable disks); magneto-optical disks; and optical disks (e.g., CD and DVD disks). The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.

[0090] To provide for interaction with a user, the subject matter described herein can be implemented on a computer having a display device, e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor, for displaying information to the user and a keyboard and a pointing device, (e.g., a mouse or a trackball), by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well. For example, feedback provided to the user can be any form of sensory feedback, (e.g., visual feedback, auditory feedback, or tactile feedback), and input from the user can be received in any form, including acoustic, speech, or tactile input.

[0091] The techniques described herein can be implemented using one or more modules. As used herein, the term “module” refers to computing software, firmware, hardware, and / or various combinations thereof. At a minimum, however, modules are not to be interpreted as software that is not implemented on hardware, firmware, or recorded on a non-transitory processor readable recordable storage medium (i.e., modulesare not software per se). Indeed “module” is to be interpreted to always include at least some physical, non-transitory hardware such as a part of a processor or computer. Two different modules can share the same physical hardware (e.g., two different modules can use the same processor and network interface). The modules described herein can be combined, integrated, separated, and / or duplicated to support various applications. Also, a function described herein as being performed at a particular module can be performed at one or more other modules and / or by one or more other devices instead of or in addition to the function performed at the particular module. Further, the modules can be implemented across multiple devices and / or other components local or remote to one another. Additionally, the modules can be moved from one device and added to another device, and / or can be included in both devices.

[0092] The subj ect matter described herein can be implemented in a computing system that includes a back-end component (e.g., a data server), a middleware component (e.g., an application server), or a front-end component (e.g., a client computer having a graphical user interface or a web browser through which a user can interact with an implementation of the subject matter described herein), or any combination of such back-end, middleware, and front-end components. The components of the system can be interconnected by any form or medium of digital data communication, e.g., a communication network. Examples of communication networks include a local area network (“LAN”) and a wide area network (“WAN”), e.g., the Internet.

Claims

Gas Compression Power Reduction System and MethodCLAIMS1. Gas compression plant (1), connectable to an electric grid (2) and to a gas production unit (3), comprising: an inlet (11), connectable to the gas production unit (3) for receiving the gas to be compressed; an outlet (12), from which the compressed gas is collected; a main compressor (13) connected to the inlet (11), for compressing the gas coming from the gas production unit (3); an electric drive module (16), connectable to the electric grid (2), for driving the main compressor (13), wherein the inlet (11), the outlet (12) and the main compressor (13) forms a main compression line (14); an recycle line (15), which connects the inlet (11) and the outlet (12) characterized in that the gas compression plant (1) further comprises a power reduction unit (4), connected in parallel to the recycle line (15), wherein the power reduction unit (4) comprises an auxiliary compressor (41) configured to remove the gas from the recycle line (15) while the main gas compressor (13) continues operating at a defined speed, to reduce the gas pressure from the main compressor (13); a high-pressure storage vessel (42) configured to store the gas removed by the auxiliary compressor (41) and release it when the pressure of the a control system (5) configured to activate and deactivate the power reduction unit (4), wherein, when the power reduction unit (4) is activated, the auxiliary compressor (41) fills the high-pressure storage vessel (42) with the gas of the main compression line (14), and wherein, when the power reduction unit (4) is deactivated, the power reduction unit (4) refills the main compression line (14) with the gas stored in the high-pressure storage vessel (42) before resuming normal operation of the main gas compressor (41).

2. The gas compression plant (1) of claim 1,Wherein, in use, the main compressor (13) operates at idle mode when power generated by the electric grid (2) is below a certain threshold, and wherein the control system (5) is configured to activate the power reduction unit (4) at the beginning of an idle mode of the main compressor (13).

3. The gas compression plant (1) of any one of the preceding claims, wherein the control system (5) comprises an recycle valve (51) connected between the inlet (11) and the main compression outlet (12), an input valve (52), connected between the inlet (11) and the main compressor (13), and an output valve (53), connected between the main compressor (13) and the outlet (12) and the main compressor (13).

4. The gas compression plant (1) of any one of the preceding claims, comprising an extraction valve (54) connected between the outlet (12) and the auxiliary compressor (41), to allow the auxiliary compressor (41) to take the gas from the main compression line (14) to be stored into the high-pressure storage vessel (42) when the power reduction unit (4) is activated, and an introduction valve (55), connected between the high-pressure storage vessel (42) and the inlet (11), to allow high-pressure storage vessel (42) to relase the gas stored back into the main compression line (14) when the power reduction unit (4) is deactivated,5. The gas compression plant (1) of any one of the preceding claims, comprising a control logic unit (U), configured to control and coordinate the control system (5).

6. The gas compression plant (1) of any one of the preceding claims, wherein the power reduction unit (4) comprises an electric motor (43), to drive the auxiliary compressor (41).

7. The gas compression plant (1) of any one of the preceding claims, wherein the electric drive module (16) comprises: an electric motor (161), for transforming the electric energy from the electric grid (2) in mechanical energy for driving the main compressor (13); and a variable speed drive system (161), to control the flow of energy from the electric grid (2).

8. The gas compression plant (1) of any one of the preceding claims, comprising a cooler (17) connected between the main compressor (13) and the outlet (12), for cooling the gas compressed by the main compressor (13).

9. The gas compression plant (1) of any one of the preceding claims, wherein the electric grid (2) comprises electric generating machines, such as wind turbine plant (21) and / or solar panel plant (22).

10. A method (100) for reducing power consumption in a gas compression plant (1) according to any one of the preceding claims, during idle mode, wherein the method (100) comprises the steps of: activating (110) the control system (5) for activating power reduction unit (4) for the auxiliary compressor (41) to fill the high-pressure storage vessel (42) with the gas of the main compression line (14); and deactivating (120) the control system (5), for the power reduction unit (4) to refill the main compression line (14) with the gas stored in the high-pressure storage vessel (42) before resuming normal operation of the main gas compressor (41).

11. The method (100) of the preceding claim, wherein the activation step (110) comprises the sub-steps of: closing (111) an input valve (52) and an output valve (53); opening (112) a recycle valve (51); opening (113) an extraction valve (54); closing (114)an introduction valve (55); activating (115) the auxiliary compressor (41), to compress the gas coming from the main compression line (14); introducing (116) the gas compressed by the auxiliary compressor (41) intothe high-pressure storage vessel (42); and reducing (125) the operating speed of the main compressor (13).

12. The method (100) of any one of claims 10 or 11, wherein the main gas compressor (13) is maintained at a defined speed while the power reduction unit (4) is activated, wherein the defined speed is preferably within 10% of its nominal operating speed.

13. The method (100) of any one of claims 10 - 12, wherein the deactivation step (120) comprises the sub-steps of: closing (121) the recycle valve (51); closing (122) the extraction valve (54); opening (123) the introduction valve (55); introducing (124) into the main compression line (14) the gas stored into the high-pressure storage vessel (42); increasing (125) the operating speed of the main compressor (13).

14. The method (100) of any one of claims 10 - 13, comprising the further steps of operating (130) the compression plant (1) in compression mode.

15. The method (100) of the preceding claim, wherein the compression mode operating step (130) comprises the further steps of: opening (131) the input valve (52) and the output valve (53); and closing (132) the introduction valve (55).

16. The method (100) of any one of claims 10 - 15, wherein, in use, the power reduction unit (4) is activated when the electric flow of the electric grid (2) fluctuates.

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