Overhung Axial Compressor Cartridge for Dirty Gas Maintenance
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Solution Overview
Problem
Centrifugal and mixed-flow compressors used in the polyethylene/polypropylene industry face challenges of large size and weight, decreased polytropic efficiency with increased flow coefficients, and maintenance difficulties due to clogging in dirty process gas conditions, particularly in axial compressors.
Innovation Solution
An overhung axial compressor design featuring a vertically split casing and a removable cartridge with a horizontally disposed shaft, bearing system, and guide vane mechanism to adjust fluid flow, reducing weight and size while simplifying maintenance by minimizing cavities and allowing easy access to moving parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If centrifugal or mixed-flow compressor design is used, then high pressure output is achieved, but weight and size increase significantly
Solution Approach 1:
The compressor is divided into a stationary casing and a removable rotating cartridge assembly. The cartridge contains the shaft, blades, and bearing system, allowing these components to be separated from the casing for independent maintenance and replacement without dismantling the entire compressor.
Solution Approach 2:
The invention transitions from traditional horizontal shaft orientation to a vertical shaft configuration where the shaft extends vertically from the bottom of the casing, with blades arranged radially outward. This dimensional change optimizes the flow path and reduces the overall footprint and weight of the compressor while maintaining high pressure output capability.
2Volume of moving object
If axial compressor design is used, then smaller size is achieved, but maintenance becomes difficult due to clogging in dirty process gas conditions
Solution Approach 1:
The compressor is divided into a stationary casing and a removable rotating cartridge assembly. The cartridge contains the shaft, blades, and bearing system, allowing these components to be separated from the casing for independent maintenance and replacement without dismantling the entire compressor.
Solution Approach 2:
The guide vane mechanism is designed to be adjustable during operation, allowing the flow angle to be optimized for different process conditions. This dynamic adjustment capability prevents clogging by adapting the flow path to match the actual gas composition and flow rate, maintaining efficient operation in dirty process gas conditions.
3Productivity
If flow coefficient is increased beyond certain point, then volume flow rate improves, but polytropic efficiency decreases
Solution Approach 1:
The guide vane mechanism is designed to be adjustable during operation, allowing the flow angle to be optimized for different process conditions. This dynamic adjustment capability prevents clogging by adapting the flow path to match the actual gas composition and flow rate, maintaining efficient operation in dirty process gas conditions.
Solution Approach 2:
The compressor is designed to operate at optimized flow coefficients through the specific geometric configuration of the blades and guide vanes. By carefully selecting the blade angle, chord length, and spacing, along with the guide vane geometry, the compressor achieves peak polytropic efficiency at the desired operating flow rate, preventing efficiency degradation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves a smaller weight and size with improved flow coefficients, reduced maintenance complexity, and enhanced performance by minimizing product buildup and allowing for easier servicing, outperforming traditional compressors in efficiency and size.
Implementation Method 1
a bearing system attached to the removable cartridge and configured to rotationally support a first end of the shaft
Implementation Method 2
a guide vane mechanism configured to connect to the removable cartridge, the guide vane mechanism being configured to adjust a flow of a fluid to the plural blades
Implementation Method 3
An overhung axial compressor design featuring a vertically split casing and a removable cartridge with a horizontal shaft and guide vane mechanism, which reduces weight and size while simplifying maintenance
Data Source
AI summary
Overhung axial compressor, chemical reactor and method for compressing a fluid. The overhung axial compressor includes a casing configured to be vertically split along a vertical axis for access to an inside of the casing and a removable cartridge. The removable cartridge is configured to fit inside the casing and to be detachably attached to the casing. The removable cartridge includes a shaft disposed along a horizontal axis, the shaft being configured to rotate about the horizontal axis, a bearing system attached to the removable cartridge and configured to rotationally support a first end of the shaft, and plural blades disposed toward a second end of the shaft such that the second end is overhung inside the casing. The compressor also includes a guide vane mechanism configured to connect to the removable cartridge, the guide vane mechanism being configured to adjust a flow of a fluid to the plural blades.