Compressor Coolant Temperature Control via Intercooler Routing
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Solution Overview
Problem
Conventional gas compressors face inefficiencies due to heat generation during compression, and existing cooling methods are limited by temperature extremes, leading to potential blockages and reduced performance, especially in varying ambient conditions.
Innovation Solution
A gas compression system with a coolant circuit that includes a pump, intercoolers, and a thermostatic or solenoid-actuated valve to manage coolant temperature, ensuring efficient heat transfer and preventing coolant freezing or overheating by routing the coolant through intercoolers based on temperature limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If contact cooling is used to improve compression efficiency, then heat removal is enhanced, but the cooling fluid may freeze in cold environments causing blockages and damage
Solution Approach 1:
The system changes the temperature parameter of the cooling fluid dynamically by routing it through a heat exchanger when ambient temperature drops below a threshold, preventing freezing while maintaining cooling effectiveness
Solution Approach 2:
A heat exchanger is introduced as an intermediary component to transfer heat from the cooling fluid to the compressed gas, allowing the cooling fluid to be warmed without directly contacting the gas stream
2Loss of energy
If contact cooling is used to remove heat during compression, then compression efficiency improves, but the cooling fluid becomes increasingly hot at high ambient temperatures reducing its effectiveness
Solution Approach 1:
The system periodically routes the cooling fluid through the heat exchanger based on temperature threshold detection, allowing the cooling fluid to be cooled when needed rather than continuously
Solution Approach 2:
A temperature sensor provides feedback on the cooling fluid temperature or ambient temperature, triggering the valve to route fluid through the heat exchanger when thresholds are exceeded, creating a closed-loop control system
3Loss of energy
If a cooling fluid is introduced into the compression cell for heat removal, then compression efficiency improves, but the system complexity increases due to additional cooling components
Solution Approach 1:
The heat exchanger serves multiple functions: it cools the cooling fluid, pre-cools incoming compressed gas, and can act as a thermal storage element, reducing the need for separate dedicated components
Solution Approach 2:
The cooling circuit is merged with the compressed gas flow path through the heat exchanger, allowing simultaneous cooling of the fluid and pre-cooling of the gas in a single integrated system
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 maintains optimal coolant temperature, enhancing compression efficiency and preventing damage by ensuring the coolant remains effective across a wide range of temperatures, thereby improving compressor performance and reliability.
Implementation Method 1
a first intercooler in thermal communication with the dryer and in fluid communication with the tank and the pump, the first intercooler structured to transfer heat from the coolant circuit to the compressed gas flow via the dryer
Implementation Method 2
One common means, known as contact cooling, is to introduce a cooling fluid into the compression process that comes into direct contact with the compressible gas and cools it by evaporative cooling
Data Source
AI summary
According to at least one aspect of the present disclosure, an apparatus for cooling a coolant for a gas compressor includes a compressor to generate a flow of compressed gas, a dryer in fluid communication with the compressor, and a coolant circuit. The coolant circuit includes a accumulator to accumulate the coolant, a pump in fluid communication with the accumulator and the compressor to circulate the coolant through the coolant circuit, a first intercooler in fluid communication with the accumulator and the pump and structured to transfer heat from the coolant circuit to the compressed gas flow via the dryer, and a valve disposed between the accumulator and the first intercooler and structured to route at least a portion of the coolant through the first intercooler depending on a temperature of the coolant relative to prescribed low and high temperature limits.