Compressed Gas Recycling via Segmented Return Lines
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Solution Overview
Problem
Existing methods for recycling compressed air in stretch blow molding machines are limited by the need for a minimum pressure feedback, preventing the reuse of all produced compressed air, especially at different pressure levels.
Innovation Solution
A method and device that separate and recycle compressed air at various pressure levels by using multiple return lines to feed recycled air into specific points within the compressor system, such as before the first pressure boosting stage or between stages, allowing for a higher recycling rate by maintaining constant pressure through buffer tanks and controlled pressure regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If compressed air is recycled using a single feedback line with minimum pressure requirement, then the system structure remains simple, but the recycling rate is limited and cannot accommodate different pressure levels
Solution Approach 1:
The single feedback line is segmented into multiple return lines (first return line 8, second return line 9, third return line 10) that divide the compressed air feedback path according to pressure levels. Each return line handles a specific pressure range, allowing comprehensive recycling of compressed air at different pressures while maintaining manageable system complexity through modular organization.
Solution Approach 2:
Different segments of the system are assigned different functional qualities based on local pressure requirements. The first return line handles lower pressure compressed air (4-7 bar), the second return line handles medium pressure (10-13 bar), and the third return line handles higher pressure compressed air. This local differentiation enables each part of the system to operate optimally within its pressure range.
2Productivity
If compressed air at different pressure levels is mixed and fed back together, then the feedback system remains simple, but pressure regulation becomes difficult and recycling efficiency decreases
Solution Approach 1:
The feedback system is segmented into pressure-specific channels with dedicated buffer tanks (buffer tank 10 for low-pressure, buffer tank 11 for medium-pressure compressed air). This segmentation prevents mixing of different pressure levels and allows independent pressure regulation for each stream, significantly improving recycling efficiency while keeping the regulation system manageable through modular design.
Solution Approach 2:
Buffer tanks serve as intermediary storage devices between the consumption point and the compression stages. These intermediaries decouple the pressure regulation requirements from the recycling flow, allowing compressed air at different pressures to be stored and fed back at appropriate pressures without direct mixing, thereby improving efficiency while simplifying pressure control.
3Productivity
If compressed air is fed back at varying pressure levels, then more compressed air can be recycled, but the pressure feed becomes unstable
Solution Approach 1:
Buffer tanks (buffer tank 10, buffer tank 11) act as intermediary storage vessels that stabilize the pressure feed. Compressed air is stored in these buffers at controlled pressures before being fed back to the compression stages. This intermediary storage decouples the variable pressure recycling from the stable pressure requirement of the compression process, enabling high recycling volumes while maintaining pressure feed stability.
Solution Approach 2:
The system changes the pressure parameter of recycled compressed air according to its origin and destination. Low-pressure compressed air (4-7 bar) from the first return line is fed before the first compression stage, while medium-pressure compressed air (10-13 bar) from the second return line is fed between compression stages. This parameter adaptation allows maximum recycling while maintaining stable operation at each compression stage.
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
This approach enables a significantly higher recycling rate of compressed air across different pressure levels, optimizing the use of recycled air and reducing pressure losses, thereby enhancing the efficiency of the recycling process.
Implementation Method 1
The booster 3 is supplied with pressurized compressed gas, subsequently compressed air, from a low-pressure compressor 5 via a low-pressure network 4. The compressed air is then brought to the required pressure in the booster 3
Implementation Method 2
the recirculated compressed gas is fed into the booster 3 at a point in the pressure increase process in the booster which corresponds to the pressure level of the recirculated compressed gas... the compressed air is then brought to the required pressure in the booster 3 and conveyed via a buffer tank 6
Data Source
Figure 1~2
AI summary
The method involves recirculating the compressed gas used in a compressed gas consumer, particularly a container blow molding machine, in a compressed gas generator. The compressed gas from the compressed gas consumer is collected separately after pressure stages and is supplied separately to pressure areas of the pressure generator (2) after pressure stages. The recirculated compressed gas is collected before feeding into the pressure generator. An independent claim is also included for a device for recycling of compressed gas from a compressed gas consumer, particularly a container blow molding machine.