Compressed Air System Combining Intercoolers and Radiator
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Solution Overview
Problem
Existing compressed air generation systems with multi-stage compression face challenges in efficiently removing high heat generation, noise control, and minimizing cooling duct requirements, especially in standalone units achieving high compression ratios like 1:40-1:50.
Innovation Solution
A compressed air generation system incorporating a multi-stage reciprocating compressor with a combi-cooler assembly that includes intercoolers and a radiator, designed as a standalone unit to efficiently manage heat dissipation, noise levels, and reduce cooling duct needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water cooling is used for multi-stage reciprocating compressed air, then the desired cooling effect is achieved, but more space is required for heat-exchanger plant and complicated piping and valve arrangements are needed
Solution Approach 1:
The patent combines the intercooler and after-cooler into a single integrated heat exchanger unit. The intercooler section cools compressed air between compression stages, while the after-cooler section cools the final compressed air discharge. This merging eliminates the need for separate cooling plants and reduces piping complexity while maintaining effective cooling.
Solution Approach 2:
The integrated heat exchanger performs multiple cooling functions simultaneously - it acts as both an intercooler for intermediate cooling and an after-cooler for final cooling. This multi-functionality reduces the overall system complexity and space requirements compared to separate dedicated cooling systems.
2Stress or pressure
If multi-stage compression is used to achieve high pressure ratios, then the required compression is achieved, but high temperatures are generated after compression that require cooling
Solution Approach 1:
The intercooler is positioned between compression stages to cool the air before it enters the next compression stage. This preliminary cooling action reduces the temperature rise during subsequent compression, improving efficiency and reducing the after-cooler load.
Solution Approach 2:
The intercooler acts as an intermediary cooling stage between the compression stages. It mediates the heat generation by removing excess heat from the compressed air before it undergoes further compression, thereby controlling the temperature profile through the compression process.
3Loss of energy
If intercooler is placed immediately after compression stage, then heat removal is efficient, but more space and cooling ducts are required
Solution Approach 1:
The patent merges the intercooler and after-cooler into a single compact heat exchanger assembly that can be integrated close to the compressor. This eliminates the need for separate distributed cooling ducts and reduces the overall space footprint while maintaining efficient heat removal through the integrated design.
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 system effectively removes high heat generated during compression, operates within specified noise limits, and simplifies installation by minimizing the need for cooling ducts, making it a viable standalone unit for high-pressure compressed air applications.
Implementation Method 1
a combi-cooler assembly (7) having at least two intercoolers (104a, 104b) and a radiator (105)
Implementation Method 2
a radiator (105)
Implementation Method 3
a radiator (105)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present disclosure relates to and envisages a compressed air generation system (100). The compressed air generation system (100) comprises a multistage reciprocating compressor (1) for providing compressed air at a high pressure. A combi-cooler assembly (7) comprising a pair of intercoolers (104a, 104b) and a radiator (105) assembly is configured to dissipate heat recovered by the cooling fluid from first reciprocating compression stage (102a), second reciprocating compression stage (102b), third reciprocating compression stage (102c) and crankcase assembly (130) of the radiator circuit.