Compressor Cooling System with Bypass Valves for Heat Recovery
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Solution Overview
Problem
Existing compressor systems lack effective cooling methods for compressors and compressed gas when ambient temperatures increase, and fail to continue cooling and heat recovery in case of water supply pump failures.
Innovation Solution
A compressor system with a control unit managing multiple valve pathways and cooling liquid circuits to maintain compressor and lubricant cooling, utilizing an aftercooler, heat recovery heat exchanger, and bypass pathways to ensure continuous cooling and heat recovery, even during high ambient temperatures or pump failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If heat recovery is performed using a heat recovery heat exchanger, then waste heat from compressed gas is recovered effectively, but the system cannot continue cooling and heat recovery when water supply pump fails or ambient temperature increases
Solution Approach 1:
The cooling liquid circulation system is segmented into multiple independent pathways: a first cooling liquid pathway for compressor cooling and a second cooling liquid pathway for aftercooler cooling with heat recovery. This segmentation allows the system to maintain essential cooling functions even when heat recovery operations are compromised by pump failures or high ambient temperatures.
Solution Approach 2:
A control unit acts as an intermediary that monitors system conditions (pump operation, ambient temperature, compressed gas temperature) and dynamically switches between heat recovery mode and bypass mode. When pump failure or high ambient temperature is detected, the control unit redirects cooling liquid through bypass pathways, ensuring continuous cooling while preventing unnecessary heat recovery operations.
2Reliability
If multiple valve pathways are added to enable bypass operations, then system reliability under pump failure is improved, but device complexity increases
Solution Approach 1:
The control unit implements multi-functionality by managing both normal heat recovery operations and emergency bypass operations through a single integrated control system. The same control unit monitors pump status, ambient temperature, compressed gas temperature, and valve positioning, eliminating the need for separate control mechanisms for each function and reducing overall system complexity.
Solution Approach 2:
The system incorporates self-service through automatic monitoring and response mechanisms. The control unit continuously monitors system conditions and automatically switches between operational modes without manual intervention. This self-service capability reduces the need for complex manual control systems and enhances reliability by ensuring rapid response to pump failures or high ambient temperature conditions.
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 compressed gas temperature below alarm levels, ensures continuous heat recovery from high-temperature sources, and reduces energy consumption by optimizing heat recovery modes.
Implementation Method 1
a cooling liquid pathway through which cooling liquid which has been cooled by a cooling heat exchanger is supplied to the compressor
Implementation Method 2
an aftercooler that cools the compressed gas discharged by the compressor
Implementation Method 3
waste heat from the cooling liquid being recovered by a heat recovery heat exchanger
Data Source
AI summary
A system has a compressor for discharging compressed gas, an aftercooler for cooling the compressed gas, a first cooling liquid pathway for supplying a cooling liquid to the compressor and for cooling the cooling liquid by means of a cooling heat exchanger, and a second cooling liquid pathway for passing the cooling liquid through the aftercooler and for recovering waste heat from the cooling liquid by means of a heat recovery heat exchanger, in which the compressor system includes a first valve and a second valve disposed in a plurality of bypass pathways connecting the first cooling liquid pathway and the second cooling liquid pathway, a third valve and a fourth valve disposed in the first cooling liquid pathway, and a control unit, and in which the control unit performs first control to close the first valve and the second valve and open the third valve and the fourth valve.