Compressor Bypass for Natural Gas Engine Energy Recovery
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Solution Overview
Problem
Turbocharged natural gas engines face energy loss and compressor surge issues due to existing bypass systems that redirect compressed air/fuel mixture back to the compressor inlet, leading to inefficient energy utilization and potential component damage.
Innovation Solution
A power system with a bypass system that includes a valve assembly and control system to selectively direct compressed air from the compressor outlet to a second turbine, allowing energy recovery and preventing compressor surge by regulating airflow based on operational parameters sensed by sensors and controlled by a controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bypass system directs compressed air/fuel mixture back to the compressor inlet, then compressor surge is avoided, but energy is lost due to unused compression work
Solution Approach 1:
The patent introduces a second turbine as an intermediary component between the compressor outlet and the exhaust system. The bypass system directs compressed air to this intermediate turbine rather than back to the compressor inlet, allowing the compression energy to be recovered and converted into rotational work that drives the exhaust turbine, thus eliminating energy waste while preventing compressor surge
Solution Approach 2:
The patent converts the previously harmful wasted compression energy into a beneficial resource. By directing compressed air through the bypass to drive the second turbine, the system transforms the energy that would have been lost into useful work that assists in driving the exhaust system, turning an energy loss problem into an energy recovery solution
2Speed
If a throttle valve is used to control air/fuel mixture flow, then engine speed is reduced, but compressor surge occurs due to abrupt flow reduction
Solution Approach 1:
The patent segments the flow control function into two separate systems: the throttle valve for controlling air/fuel mixture flow to the engine, and the bypass system with second turbine for managing compressor outlet flow. This segmentation allows independent optimization of each function, enabling engine speed control without triggering compressor surge conditions
Solution Approach 2:
The bypass system with the second turbine acts as an intermediary mechanism that provides an alternative flow path for compressed air. When engine speed needs to be reduced, the system can open the bypass valve to direct compressed air through the second turbine, which absorbs the excess flow and prevents compressor surge, while the throttle valve independently controls the air/fuel mixture flow to the engine
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 recovers energy by directing compressed air to drive the second turbine, reducing the risk of compressor surge and enhancing overall efficiency and component longevity by optimizing airflow management.
Implementation Method 1
A turbocharger having a compressor that compresses the air flowing into the engine
Implementation Method 2
The turbocharger typically also includes a turbine connected to the compressor and driven by an exhaust of the engine
Data Source
AI summary
A power system includes a natural gas engine, a first turbine receiving an exhaust from the engine, and a second turbine having an inlet fluidly connected to an outlet of the first turbine. The power system also includes a compressor driven by the first turbine. The compressor has an outlet fluidly connected to the engine. The power system further includes a bypass system directing a fluid from the outlet of the compressor to the inlet of the second turbine.