Positive displacement blowers or compressors having porous media elements

Abstract

A positive displacement compressor or blower can include multiple lobes or rotors. The rotors or lobes can include porous media elements to facilitate providing a pre-selected clearance between adjacent moveable lobes or rotors via a film of gas that can be output via the porous media. Embodiments can be adapted to avoid use of timing gears or petroleum based lubricants.

Description

POSITIVE DISPLACEMENT BLOWERS OR COMPRESSORSHAVING POROUS MEDIA ELEMENTSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to U.S. Provisional Application 63 / 748,474 filed January 23, 2025, which is incorporated by reference herein.FIELD OF THE INVENTION

[0002] The present innovation relates to compressors such as positive displacement blowers or positive displacement compressors.BACKGROUND OF THE INVENTION

[0003] Compressors can include a screw type compressor or a lobe blower type compressor. These types of compressors can facilitate compression of a fluid by reducing the volume from the suction side of the compressor to the discharge side of the compressor, which raises the pressure of the fluid.

[0004] For example, lobe blowers can have a multiple number of lobes that operate together at a specific rotating speeds. These types of blowers can compress a gaseous fluid through the use of two or more lobes, or screws, that move a fluid received via an inlet port to output that fluid from a discharge port. Some blowers are designed with 3 rotors with an equal number of lobes. The discharge pressure is often determined by the process requirements but is also partially determined by the geometry of the lobes, the speed, and the number of lobes.

[0005] Another type of positive displacement blower or compressor is called a screw compressor. A screw compressor often utilizes two helical designed rotors to move the fluid from a low-pressure suction port to a high pressure discharge port. There are two screws, a male rotor and a female rotor that work together to compress the fluid.SUMMARY OF THE INVENTION

[0006] Positive displacement blowers or compressors can require operation with very small clearances between the rotors or lobes. A clearance is often pre-selected in order to keep the rotors or lobes from damaging each other as they turn. A large clearance can reduce the power efficiency due to gas leakages that may occur as the fluid is compressed as it is moved from the discharge side to suction side. However, a clearance that is too small may have an effect of damaging the rotors or lobes if they rub or touch while rotating because the rotors or lobes are not designed for metal-to-metal contact. Temperature changes in the compression process can also affect the clearance between the rotors.

[0007] Conventionally, there are two basic schemes that may be utilized to keep the rotors (or lobes) from touching metal to metal. The first method is to include a set of timing gears. The timing gears are usually installed on each rotor at one end of the casing. In addition tothe method of keeping the rotors at some clearance during rotation, the timing gears can also facilitate transferring the required energy or power for rotation of the second rotor or second lobe.

[0008] For example, in a positive displacement blower or compressor, there is a drive shaft that is attached to the motor that is rotated by the motor. The drive shaft transmits all the torque and energy to the two lobe rotors. The timing gears can be positioned so that the first timing gear coupled to a first lobe or rotor can transfer the required torque and power to the secondary rotor / lobe system via having intermeshing teeth with the timing gear connected to the second lob or rotor. A petroleum based lubricant (e.g. oil) may also be used to help the timing gears rotate via intermeshing teeth without fracturing or failing. The petroleum based lubricant may be used to lubricate the mating gear teeth and prevent scuffing, ear, and pitting damage to gear teeth surfaces due to the metal-to-metal contact that may occur. Oil viscosity can increase with pressure and may separate the mating gear teeth. The oil can also be used to cool the timing gear teeth and prevent excessive teeth temperature and overheating of the oil.

[0009] Another approach that may be utilized to keep the rotors or lobes of a screw compressor or blower from touching is by injecting a petroleum based lubricant between the rotors so that one rotor can drive the other rotor via a lubricating fluid film. The petroleum based lubricant that is used is typically a petroleum based oil or a synthetic oil. In this type of scheme, the timing gears are not needed as one rotor will drive the other rotor directly via the lubricated film on the rotor surfaces.

[0010] Major causes of failures for positive displacement compressors or blowers can occur in the lubrication areas. These failures can include inadequate amounts of lubrication, the wrong lubrication, minimal maintenance on lubrication (oil changes), and dirt in the lubrication. Timing gears can be especially prone to failure with lubrication issues.

[0011] We have determined that positive displacement compressors or blowers can be improved by designing such devices to avoid use of a petroleum based lubricant (e.g. oil or grease) and / or to avoid use of timing gears. By avoiding such elements, significant failure modes can be avoided to provide a more reliable compressor or blower. Embodiments can also permit a more efficient operation by removing a need to maintain or monitor the utilization of a petroleum based lubricant (e.g. oil) and / or how dirty that petroleum based lubricant has gotten during use.

[0012] For example, embodiments of our compressor or blower can utilize porous media positioned on different teeth of gears or on different lobes or rotors of a positive displacement blower. The porous media can be positioned so that a gas (e.g. air, nitrogen gas, a gas that is the same type of gas as being compressed by the blower or compressor, other type of suitable gas, etc.) can be injected through the porous media to provide a film of gas that canprovide a gaseous lubricant that can form a gaseous film or gaseous barrier that can provide a pre-selected clearance between the rotors or lobes that can prevent metal-to-metal contact that can damage the teeth of the rotors or the lobes. The gas may be injected at a pressure that is higher than the operating pressure of the chamber in which the rotors or lobes are operating. The porous media can also be utilized such that the friction between mating surfaces can be relatively low. Also, utilization of a gas via the porous media can also avoid dirt from being inserted into the compressor or blower as compared to devices that may utilize a petroleum based lubricant or petroleum based lubricant system (e.g. a system using grease, oil, or synthetic oil, etc.).

[0013] In a first aspect, a positive displacement compressor or blower apparatus can be provided. Embodiments of the apparatus can include a first rotor or lobe connected to a first shaft for rotation of the first rotor or lobe and a second rotor or lobe connected to a second shaft for rotation of the second rotor or lobe. The first rotor or lobe and the second rotor or lobe can be positioned in a compression chamber. The compression chamber can be defined in a housing in some embodiments. The second rotor or lobe can have porous media positioned on a first end of the second rotor or lobe for facing the first rotor or lobe during rotation of the first rotor or lobe that occurs simultaneously with rotation of the second rotor or lobe. The porous media of the first end of the second rotor or lobe can be connectable to a porous media conduit arrangement to receive gas to output the gas from the porous media to form a gaseous film or barrier between the first and second rotors or lobes during rotation of the first rotor or lobe and rotation of the second rotor or lobe.

[0014] In some embodiments, the apparatus can be configured as a compressor or as a blower. In some embodiments, the compression chamber can be in fluid communication with an inlet port to receive gas from a suction side of the housing and also be in fluid communication with an outlet port positioned on a discharge side of the housing to output a compressed gas from the compression chamber.

[0015] The number of rotors or lobes can include more than two rotors or lobes in some embodiments. For example, there can be a third rotor or lobe positioned in the combustion chamber that can rotate simultaneously with rotation of the first rotor or lobe. As another example, there can be a third rotor or lobe positioned in the combustion chamber that can rotate simultaneously with rotation of the second rotor or lobe.

[0016] In some embodiments, the first shaft can be connected to a motor or a drive shaft of a motor to drive rotation of the first rotor or lobe and the second shaft can be a driven shaft that facilitates rotation of the second rotor or lobe that can be driven via rotation of the first rotor or lobe. In some other embodiments, the second shaft can be connected to a motor or a drive shaft of a motor to drive rotation of the second rotor or lobe and the first shaft can bea driven shaft that facilitates rotation of the first rotor or lobe that can be driven via rotation of the second rotor or lobe.

[0017] In a second aspect, the porous media can also be positioned in other portions of the second rotor or lobe. For example, the second rotor or lobe can also have porous media positioned on a second end of the second rotor or lobe for facing the first rotor or lobe during rotation of the first rotor or lobe that occurs simultaneously with rotation of the second rotor or lobe. The porous media of the second end of the second rotor or lobe can be connectable to the porous media conduit arrangement to receive the gas to output the gas from the porous media of the second end to form a gaseous film or barrier between the first and second rotors or lobes during rotation of the first rotor or lobe and rotation of the second rotor or lobe.

[0018] In some embodiments, the first rotor or lobe can also include porous media. For example the first rotor or lobe can include porous media positioned on a first end of the first rotor or lobe for facing the second rotor or lobe during rotation of the first rotor or lobe that occurs simultaneously with rotation of the second rotor or lobe and / or the first rotor or lobe can include porous media positioned on a second end of the first rotor or lobe for facing the second rotor or lobe during rotation of the first rotor or lobe that occurs simultaneously with rotation of the second rotor or lobe.

[0019] In a third aspect, the second rotor or lobe can be positioned adjacent to the first rotor or lobe so that rotation of the first rotor or lobe drives rotation of the second rotor or lobe.

[0020] In a fourth aspect, seals of the positive displacement compressor or blower apparatus can also include porous material connectable to the porous media conduit arrangement to receive gas to output the gas from the porous media of the seals to provide seals. In some embodiments, the seals can include shaft seals.

[0021] In a fifth aspect, bearings of the positive displacement compressor or blower apparatus can also include porous material connectable to the porous media conduit arrangement to receive gas to output the gas from the porous media of the bearings.

[0022] In a sixth aspect, a source of the gas connectable to the porous media conduit arrangement can be included in the apparatus. In some embodiments, the source of gas can be gas provided via a slip stream of the compressed gas output from a discharge port that can be fluidly connected to the porous media conduit arrangement via a slip stream conduit and / or gas providable via a storage tank of gas or other source of gas that can be connected to the porous media conduit arrangement.

[0023] For example, in some embodiments, there can be a slip stream conduit connected between the porous media conduit arrangement and a discharge conduit so a portion of the compressed gas outputtable from the discharge conduit is routable to the porous media. A booster can be positioned to increase a pressure of the portion of the compressed gas routable to the porous media so the pressure of the portion of the compressed gas output from thebooster for feeding to the porous media is greater than a pressure of the compression chamber.

[0024] In a seventh aspect, the positive displacement compressor or blower apparatus can be configured so that it does not utilize any timing gears for rotation of the first lobe or rotor and rotation of the second lobe or rotor.

[0025] In an eighth aspect, the positive displacement compressor or blower apparatus can be configured so that it does not utilize any petroleum based lubricant for rotation of the first lobe or rotor and / or rotation of the second lobe or rotor.

[0026] In a ninth aspect, the apparatus of the first aspect can include one or more features of the second aspect, third aspect, fourth aspect, fifth aspect, sixth aspect, seventh aspect, and / or eighth aspect. Yet other embodiments can also include other features or elements. Examples of such other elements or features can be appreciated from the exemplary embodiments discussed herein.

[0027] In a tenth aspect, a positive displacement compressor or blower apparatus can include a first rotor or lobe connected to a first timing gear for rotation of the first rotor or lobe and a second rotor or lobe connected to a second timing gear for rotation of the second rotor or lobe. The first timing gear can have teeth that are intermeshable with teeth of the second timing gear. The first rotor or lobe and the second rotor or lobe can be positioned in a compression chamber. The apparatus can also have at least one of: (a) the first timing gear can have porous media positioned in the teeth of the first timing gear and / or (b) the second timing gear can have porous media positioned in the teeth of the second timing gear. The porous media of the first timing gear and / or the second timing gear can be connectable to a porous media conduit arrangement to receive gas to output the gas from the porous media to form a gaseous film or barrier between intermeshed teeth of the first and second timing gears during rotation of the first timing gear and the second timing gear.

[0028] In an eleventh aspect, the first timing gear can be positioned adjacent to the second timing gear so that rotation of the first timing gear drives rotation of the second timing gear.

[0029] In a twelfth aspect, seals of the positive displacement compressor or blower apparatus also include porous material connectable to the porous media conduit arrangement to receive gas to output the gas from the porous media of the seals to provide seals. In some embodiments, the seals can include shaft seals.

[0030] In a thirteenth aspect, bearings of the positive displacement compressor or blower apparatus can also include porous material connectable to the porous media conduit arrangement to receive gas to output the gas from the porous media of the bearings.

[0031] In a fourteenth aspect, embodiments can include a source of the gas that is connectable to the porous media conduit arrangement. In some embodiments, a slip stream conduit can be connected between the porous media conduit arrangement and a dischargeconduit so a portion of the compressed gas outputtable from the discharge conduit is routable to the porous media conduit arrangement. A booster can also be positioned to increase a pressure of the portion of the compressed gas routable to the porous media conduit arrangement (e.g. so the pressure of the portion of the compressed gas output from the booster for feeding to the porous media conduit arrangement is greater than a pressure of the compression chamber or a pressure of a chamber that houses the timing gears, etc.).

[0032] In a fifteenth aspect, the positive displacement compressor or blower apparatus can be configured so that it does not utilize any petroleum based lubricant for rotation of the timing gears.

[0033] In a sixteenth aspect, the positive displacement compressor or blower apparatus can be configured so that it does not utilize any petroleum based lubricant for rotation of the first lobe or rotor and / or rotation of the second lobe or rotor.

[0034] In a seventeenth aspect, the apparatus of the tenth aspect can include one or more features of the eleventh aspect, twelfth aspect, thirteenth aspect, fourteenth aspect, fifteenth aspect, and / or sixteenth aspect. Yet other embodiments can also include other features or elements. Examples of such other elements or features can be appreciated from the exemplary embodiments discussed herein.

[0035] In an eighteenth aspect, a method of operating a positive displacement compressor or blower can be provided. Embodiments of the positive displacement compressor or blower apparatus can be utilized in embodiments of the method. In some embodiments, the method can include feeding gas at a higher pressure than an operating pressure of a compression chamber to porous media of at least one rotor or lobe that is rotatable in the compression chamber to form a gaseous film or barrier between rotors or lobes within the compression chamber during rotation of the rotors or lobes or feeding gas to porous media of at least one first timing gear to form a gaseous film or barrier between teeth of the at least one first timing gear and teeth of at least one second timing gear that intermesh with the teeth of the at least one first timing gear.

[0036] Embodiments of the method can also include other features or elements. Embodiments of the method can also include other steps or processing elements.

[0037] It should be appreciated that embodiments of the apparatus and method can be configured to utilize elements of a distributed control system (DCS) and / or automated control system. Embodiments may utilize controllers, sensors, and / or other communication device elements or control device elements to monitor operations and / or control operations, for example.

[0038] Other details, objects, and advantages of the apparatuses and processes, and methods of making and using the same will become apparent as the following description of certain exemplary embodiments thereof proceeds.BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Exemplary embodiments of a positive displacement compressor or blower and methods of making and using the same are shown in the drawings included herewith. It should be understood that like reference characters used in the drawings may identify like components.

[0040] Figure 1 (which can also be referred to as FIG. 1) is a schematic illustration of a first exemplary embodiment of the compressor apparatus.

[0041] Figure 2 (which can also be referred to as FIG. 2) is a schematic illustration of a first exemplary embodiment of a lobe or rotor arrangement that can be utilized in the first exemplary embodiment of the compressor apparatus.

[0042] Figure 3 (which can also be referred to as FIG. 3) is a schematic illustration of a second exemplary embodiment of a lobe or rotor arrangement that can be utilized in the first exemplary embodiment of the compressor apparatus.

[0043] Figure 4 (which can also be referred to as FIG. 4) is a flow chart illustrating an exemplary embodiment of a method of operating a positive displacement compressor or blower.

[0044] Figure 5 (which can also be referred to as FIG. 5) is a flow chart illustrating another exemplary embodiment of a method of operating a positive displacement compressor or blower.DETAILED DESCRIPTION OF THE INVENTION

[0045] Referring to Figures 1-3, a compressor apparatus can be configured to utilize gas to form a film of gas between rotatable components (e.g. lobes, rotors, or timing gears) so that petroleum based lubricant use to facilitate rotation of such elements can be avoided. The compressor apparatus can be configured as a positive displacement blower or compressor. For instance, the compressor apparatus can include a compressor or blower that has a housing, a suction side, and a discharge side. A feed fluid can be fed to the suction side, passed through a compression chamber having moveable rotors or lobes, and subsequently output from the discharge side at a higher pressure. The lobes or rotors can rotate to help drive the fluid through the compression chamber and through the discharge side outlet, or port, so that the discharged fluid is at the higher pressure as compared to the pressure of the feed fluid fed to the suction side of the compressor or blower. The fluid that can be compressed can be a gaseous fluid (e.g. air, methane, hydrogen, natural gas, nitrogen, oxygen, etc.).

[0046] The compressor or blower can also include a porous media conduit arrangement (PMC) that can be positioned so that gas can be fed to porous media positioned in the rotors or blowers or positioned in timing gears connected to the rotors or blowers. In some embodiments, the porous media can be a sintered material that allows for a gaseous fluid toflow through the material of the porous media in such a way that it develops a gas barrier on its surface in order to support another element. The media and the structure around it can support another material on a cushion of gas via the gas barrier (or gas film) that can be formed via the gas passed through the porous media. This gaseous boundary can be provided so that petroleum based lubricant (e.g. oil) is not needed.

[0047] In some embodiments, the porous media conduit arrangement can be arranged and configured to permit a gas to be passed through the porous media to provide a pre-selected clearance between the rotors or lobes to avoid metal-to-metal contact while also permitting a driven rotor or lobe that is rotated via a drive shaft coupled to a motor to drive rotation of the other rotor(s) or lobe(s). In some embodiments, the porous media conduit arrangement can include at least one gas distribution conduit that may include holes or chambers defined in at least one shaft to which at least one of the rotors, lobes, or timing gears may be connected and may also include pathways define in the body of the lobe, rotor, or timing gear for directing gas to the porous media. The gas distribution conduit of the porous media conduit arrangement PMC can be positioned to receive pressurized gas from a source of gas for passing that gas to the porous media.

[0048] As another example, the porous media conduit arrangement can be configured to permit a gas to be passed through the porous media to provide a pre-selected clearance between the intermeshing teeth of timing gears coupled to the rotors or lobes to avoid metal-to-metal contact while also permitting a timing gear that is rotated via a drive shaft coupled to a motor to drive rotation of the other timing gear(s). For such an embodiment, the timing gear can be coupled to a respective lobe or rotor so that rotation of the timing gear causes rotation of the lobe or rotor to which that timing gear is attached.

[0049] In some embodiments, the gas utilized for passing to the porous media via the porous media conduit arrangement PMC can be gas from a source of gas. Such a gas can be a storage vessel or storage tank of the gas that may be fed to the porous media at a higher pressure than the operating pressure of the compression chamber. In some embodiments, the gas from the source of gas can be a process gas received from another plant element (e.g. gas from an air separation unit, etc.).

[0050] In other embodiments, the source of gas may include a storage tank of liquid that may be heated to a vaporize the liquid to feed the ga formed via vaporization of the liquid to the porous media. In such an embodiment, at least one heat exchanger or vaporizer may be utilized to vaporize the fluid into a gas.

[0051] In yet other embodiments, a portion of the compressed fluid output from the discharge side of the compressor or blower can be split from the output compressed fluid for being fed to the porous media via the porous media conduit arrangement PMC. In such an embodiment, a slip stream conduit SC can be connected between the porous media conduit arrangementPMC and the compressed fluid output conduit so a slip stream of the compressed fluid can be routed to the porous media. In such an embodiment, a booster compressor (Booster) can be provided to further increase the pressure of the compressed gas being fed to the porous media so that the gas is at a pre-selected compression chamber delivery pressure for being fed to the porous media.

[0052] Figure 2 illustrates an example of lobes or rotors having porous media. The compression chamber can be configured so that a first drive lobe or rotor is positioned in the compression chamber and is coupled to a rotatable drive shaft that is rotatable to drive rotation of the first drive lobe or rotor. The drive shaft, or driver shaft, can be connected to a motor that can cause the drive shaft to rotate. A second driven lobe or rotor can also be positioned in the combustion chamber to rotate within the combustion chamber. The second driven lobe or rotor can be positioned to rotate simultaneously with rotation of the first drive lobe or rotor. For example, the second driven lobe or rotor can be positioned so that rotation of the first drive lobe or rotor causes the second driven lobe or rotor to rotate. The rotors or lobes can be positioned for rotation so that a petroleum based lubricant that includes oil (e.g. grease, oil, synthetic oil, etc.) is not necessary or needed to facilitate the rotation of the lobes or rotors.

[0053] For example, a driven lobe or rotor can be configured to include porous media at a first end that is positioned to be adjacent to and engaged with a drive lobe or rotor so that the rotation of the drive lobe or rotor can drive rotation of the driven rotor or lobe. The driven rotor or lobe can also have porous media at a second end that is opposite its first end. The porous media at the second end can be positioned to be adjacent to and engaged with the drive lobe or rotor so that the rotation of the drive lobe or rotor can drive rotation of the driven rotor or lobe. The porous media can be sintered onto, formed in, or otherwise attached or incorporated into the different ends of the rotor.

[0054] The porous media at opposite ends of the rotor or lobe can be coupled to a gas distribution conduit of the porous media conduit arrangement PMC. The gas distribution conduit can be positioned and configured so that gas received from the source of gas or the slip stream of the compressed gas can be passed to the porous media and output from the porous media to form a gaseous film between the first drive rotor or lobe and the second driven rotor or lobe. This gaseous film can be formed to define a pre-selected clearance between the first and second rotors or lobes so that metal-to-metal contact between the rotors or lobes can be avoided while rotation of the first driven lobe or rotor can still cause the second driven rotor or lobe to rotate. In the embodiment of Figure 2, no timing gears may be needed or utilized to facilitate rotation of the rotors or lobes. Instead, the direct engagement of the first and second rotors via the gaseous film provided by the porous media and gas passed to the porous media may be utilized to facilitate a desired rotation of the rotors or lobes without metal-to-metal contact between the rotors or lobes occurring.

[0055] In some embodiments, porous media and a gas distribution conduit of a porous media conduit arrangement PMC can also be provided on the drive rotor or lobe in some embodiments (shown in broken line in Figure 2). For example, the porous media can be provided on opposite ends of the drive rotor or lobe to facilitate formation of the film of gas between the rotors or lobes during rotation of the rotors or lobes. The porous media can be provided in the drive rotor or lobe instead of having porous media on the driven rotor or lobe or can be provided in combination with having the porous media on the driven rotor or lobe for formation of the gas film, or gas barrier to prevent metal-to-metal contact between the rotors or lobes while rotation of the first driven lobe or rotor can still cause the second driven rotor or lobe to rotate.

[0056] Figure 3 illustrates an exemplary embodiment in which the timing gears may be utilized. In such an embodiment, porous media can be included in the teeth for at least one of the timing gears (e.g. at least one first timing gear). One of the timing gears can be coupled to a drive shaft of a motor so that rotation of the drive shaft can drive rotation of that drive timing gear. Other timing gears (e.g. at least one second timing gear) may rotate via intermeshed teeth or other operable engagement the gears may have to the drive timing gear. The porous media can be connected to the porous media conduit arrangement PMC to receive gas for the gas to be output from the porous media to form a gaseous film between the intermeshed teeth of the timing gears. The formed gaseous film can prevent metal-to-metal contact and also help cool the gear teeth when the timing gears are rotated to drive rotation of the lobes or rotors to which the timing gears are connected. Such a configuration can permit the timing gears to be rotated and cooled without use of an oil or other type of petroleum based lubricant.

[0057] Figures 4 and 5 illustrate different exemplary embodiments of methods of operating a positive displacement blower or compressor. Embodiments of the compressor apparatus shown in Figure 1 and the compressor or blower arrangements shown in Figures 2 and 3 can be utilized in embodiments of these methods.

[0058] In the embodiment of Figure 4, porous media can be positioned on at least one lobe or rotor to be driven by rotation of a drive lobe or rotor in a first step S1. The porous medica can be connected to a porous media conduit arrangement PMC so that gas can be fed to the porous media and output from the porous media to provide a film of gas between adjacent rotors or lobes in a second step S2. In a third step S3, gas can be fed to the porous media while the rotors or lobes are rotated to provide a gaseous film between adjacent rotors or lobes that provides a pre-selected clearance that can avoid or prevent metal-to-metal contact between the moving rotors or lobes.

[0059] In the embodiment of Figure 5, porous media can be positioned on at least one first timing gear in a first step ST1. Each timing gear can be connected to a respective lobe orrotor to drive rotation of the lobe or rotor. The porous media can be positioned on the different teeth of the first timing gear(s), for example. The porous medica can be connected to a porous media conduit arrangement PMC so that gas can be fed to the porous media and output from the porous media to provide a film of gas between adjacent timing gears (e.g. between intermeshing teeth of adjacent timing gears, between teeth of a first timing gear intermeshed with teeth of a second timing gear, etc.) in a second step ST2. In a third step ST3, gas can be fed to the porous media while the timing gears are rotated to provide a gaseous film between adjacent timing gears (e.g. between intermeshed teeth of different timing gears) that provides a pre-selected clearance that can avoid or prevent metal-to-metal contact between the moving timing gears while rotors or lobes to which the timing gears are connected are rotated.

[0060] Embodiments of the method can include feeding gas at a higher pressure than an operating pressure of a compression chamber to porous media of at least one rotor or lobe that is rotatable in the compression chamber to form a gaseous film or barrier between rotors or lobes within the compression chamber during rotation of the rotors or lobes. Embodiments of the method may also, or alternatively, include feeding gas to porous media of at least one first timing gear to form a gaseous film or barrier between teeth of the at least one first timing gear and teeth of at least one second timing gear that intermesh with the teeth of the at least one first timing gear. The pressure at which the gas is provided to the porous media can be pre-selected to provide gaseous film or gas barrier of a pre-selected size or thickness.

[0061] Embodiments can also utilize other features or elements. For example, the porous media can also be included in various shaft seals or bearings and be connected to the porous media gas conduit arrangement PMC to facilitate a feed of gas to provide a film of gas for the different seals or bearings.

[0062] The porous media can be a sintered material that is porous so that gas can pass through the material. The porous media can be, for example, porous carbon material, a porous metal material, a porous ceramic material, a porous composite material, or another type of porous material. The porous media can be integrated into a rotor or timing gear or other element. In some embodiments, an entire body of the timing gear or rotor may be composed of the porous media. In other embodiments, only selected portions of the timing gear, rotor, lobe, or seal may be composed of the porous material (e.g. via sintering, integral attachment, fastening, etc.).

[0063] It should also be appreciated that modifications to embodiments of the compressor or blower apparatus and processes of operating the same can also be made to meet a particular set of criteria for different embodiments of the apparatus or process. For instance, embodiments can be configured to be utilized in conjunction with a preferred type of automated process control scheme and / or distributed control scheme and the size or type ofthe equipment can be modified to meet a particular set of design criteria as well. As another example, the number of lobes or rotors that may be utilized in an embodiment can be adapted to meet a particular set of design criteria. As yet another example, the sizing and operational capacity of a compressor or blower can be adapted to meet a particular set of design criteria.

[0064] As yet another example, it is contemplated that a particular feature described, either individually or as part of an embodiment, can be combined with other individually described features, or parts of other embodiments. The elements and acts of the various embodiments described herein can therefore be combined to provide further embodiments. Thus, while certain exemplary embodiments of the process, apparatus, and methods of making and using the same have been shown and described above, it is to be distinctly understood that the invention is not limited thereto but may be otherwise variously embodied and practiced within the scope of the following claims.

Claims

CLAIMS1. A positive displacement compressor or blower apparatus, comprising:a first rotor or lobe connected to a first shaft for rotation of the first rotor or lobe; a second rotor or lobe connected to a second shaft for rotation of the second rotor or lobe,the first rotor or lobe and the second rotor or lobe positioned in a compression chamber;the second rotor or lobe having porous media positioned on a first end of the second rotor or lobe for facing the first rotor or lobe during rotation of the first rotor or lobe that occurs simultaneously with rotation of the second rotor or lobe;the porous media of the first end of the second rotor or lobe connectable to a porous media conduit arrangement to receive gas to output the gas from the porous media to form a gaseous film or barrier between the first and second rotors or lobes during rotation of the first rotor or lobe and rotation of the second rotor or lobe.

2. The positive displacement compressor or blower apparatus of claim 1 , wherein the second rotor or lobe also has porous media positioned on a second end of the second rotor or lobe for facing the first rotor or lobe during rotation of the first rotor or lobe that occurs simultaneously with rotation of the second rotor or lobe;the porous media of the second end of the second rotor or lobe connectable to a porous media conduit arrangement to receive gas to output the gas from the porous media of the second end to form a gaseous film or barrier between the first and second rotors or lobes during rotation of the first rotor or lobe and rotation of the second rotor or lobe.

3. The positive displacement compressor or blower apparatus of claim 1 , wherein the second rotor or lobe is positioned adjacent to the first rotor or lobe so that rotation of the first rotor or lobe drives rotation of the second rotor or lobe.

4. The positive displacement compressor or blower apparatus of claim 1 , wherein seals of the positive displacement compressor or blower apparatus also include porous material connectable to the porous media conduit arrangement to receive gas to output the gas from the porous media of the seals to provide seals.

5. The positive displacement compressor or blower apparatus of claim 4, wherein the seals include shaft seals.

6. The positive displacement compressor or blower apparatus of claim 1 , wherein bearings of the positive displacement compressor or blower apparatus also include porous material connectable to the porous media conduit arrangement to receive gas to output the gas from the porous media of the bearings.

7. The positive displacement compressor or blower apparatus of claim 1 , comprising:a source of the gas connectable to the porous media conduit arrangement.

8. The positive displacement compressor or blower apparatus of claim 7, also comprising:a slip stream conduit connected between the porous media conduit arrangement and a discharge conduit so a portion of the compressed gas outputtable from the discharge conduit is routable to the porous media.

9. The positive displacement compressor or blower apparatus of claim 8, also comprising:a booster positioned to increase a pressure of the portion of the compressed gas routable to the porous media so the pressure of the portion of the compressed gas output from the booster for feeding to the porous media is greater than a pressure of the compression chamber.

10. The positive displacement compressor or blower apparatus of claim 1 , also comprising:a slip stream conduit connected between the porous media conduit arrangement and a discharge conduit so a portion of the compressed gas outputtable from the discharge conduit is routable to the porous media.

11. The positive displacement compressor or blower apparatus of claim 10, also comprising:a booster positioned to increase a pressure of the portion of the compressed gas routable to the porous media so the pressure of the portion of the compressed gas output from the booster for feeding to the porous media is greater than a pressure of the compression chamber.

12. The positive displacement compressor or blower apparatus of claim 1, wherein the positive displacement compressor or blower apparatus does not utilize any timing gears for rotation of the first lobe or rotor and rotation of the second lobe or rotor.

13. The positive displacement compressor or blower apparatus of claim 1, wherein the positive displacement compressor or blower apparatus does not utilize any petroleum based lubricant for rotation of the first lobe or rotor and / or rotation of the second lobe or rotor.

14. A positive displacement compressor or blower apparatus, comprising:a first rotor or lobe connected to a first timing gear for rotation of the first rotor or lobe; a second rotor or lobe connected to a second timing gear for rotation of the second rotor or lobe,the first timing gear having teeth that are intermeshable with teeth of the second timing gear;the first rotor or lobe and the second rotor or lobe positioned in a compression chamber;at least one of:the first timing gear having porous media positioned in the teeth of the first timing gear, andthe second timing gear having porous media positioned in the teeth of the second timing gear; andthe porous media of the first timing gear and / or the second timing gear connectable to a porous media conduit arrangement to receive gas to output the gas from the porous media to form a gaseous film or barrier between intermeshed teeth of the first and second timing gears during rotation of the first timing gear and the second timing gear.

15. The positive displacement compressor or blower apparatus of claim 14, wherein the the first timing gear is positioned adjacent to the second timing gear so that rotation of the first timing gear drives rotation of the second timing gear.

16. The positive displacement compressor or blower apparatus of claim 14, wherein seals of the positive displacement compressor or blower apparatus also include porous material connectable to the porous media conduit arrangement to receive gas to output the gas from the porous media of the seals to provide seals.

17. The positive displacement compressor or blower apparatus of claim 14, wherein the seals include shaft seals.

18. The positive displacement compressor or blower apparatus of claim 14, wherein bearings of the positive displacement compressor or blower apparatus also include porous material connectable to the porous media conduit arrangement to receive gas to output the gas from the porous media of the bearings.

19. The positive displacement compressor or blower apparatus of claim 14, comprising: a source of the gas connectable to the porous media conduit arrangement.

20. The positive displacement compressor or blower apparatus of claim 19, also comprising:a slip stream conduit connected between the porous media conduit arrangement and a discharge conduit so a portion of the compressed gas outputtable from the discharge conduit is routable to the porous media conduit arrangement.

21. The positive displacement compressor or blower apparatus of claim 20, also comprising:a booster positioned to increase a pressure of the portion of the compressed gas routable to the porous media conduit arrangement.

22. The positive displacement compressor or blower apparatus of claim 14, also comprising:a slip stream conduit connected between the porous media conduit arrangement and a discharge conduit so a portion of the compressed gas outputtable from the discharge conduit is routable to the porous media conduit arrangement.

23. The positive displacement compressor or blower apparatus of claim 22, also comprising:a booster positioned to increase a pressure of the portion of the compressed gas routable to the porous media conduit arrangement.

24. The positive displacement compressor or blower apparatus of claim 14, wherein the positive displacement compressor or blower apparatus does not utilize any petroleum based lubricant for rotation of the timing gears.

25. The positive displacement compressor or blower of claim 24, wherein the positive displacement compressor or blower apparatus does not utilize any petroleum based lubricant for rotation of the first lobe or rotor and / or rotation of the second lobe or rotor.

26. A method of operating a positive displacement compressor or blower, comprising:feeding gas at a higher pressure than an operating pressure of a compression chamber to porous media of at least one rotor or lobe that is rotatable in the compression chamber to form a gaseous film or barrier between rotors or lobes within the compression chamber during rotation of the rotors or lobes; orfeeding gas to porous media of at least one first timing gear to form a gaseous film or barrier between teeth of the at least one first timing gear and teeth of at least one second timing gear that intermesh with the teeth of the at least one first timing gear.

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