Compressor Dryer Regeneration Using Intercooler Heat Exchange
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Solution Overview
Problem
Existing compressor installations face issues with inadequate regeneration of drying agents due to insufficient temperature of the regeneration gas, leading to moisture buildup and suboptimal drying cycles, exacerbated by energy-consuming electric heaters or reduced intercooler cooling, which can worsen moisture content in the gas.
Innovation Solution
Incorporating a heat exchanger upstream of the intercooler to heat the compressed gas before the last compressor element, with a control unit to manage the heating process based on predetermined parameters, ensuring efficient moisture removal and optimal regeneration gas temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the cooling capacity of the intercooler is reduced to increase regeneration gas temperature, then the temperature of the regeneration gas increases, but less moisture is removed from the compressed gas
Solution Approach 1:
The cooling process is divided into two separate stages: first the intercooler cools the compressed gas to remove moisture, then a separate heating section reheats the gas before it enters the dryer. This segmentation allows both moisture removal and temperature increase to be achieved independently without compromising either function.
Solution Approach 2:
The intercooler performs the moisture removal action beforehand, before the gas enters the heating section. By completing the cooling and condensation of moisture in advance, the subsequent heating process can focus solely on increasing the temperature for regeneration without worrying about moisture removal.
2Temperature
If an electric heater is provided in the regeneration line to increase regeneration gas temperature, then the temperature of the regeneration gas increases, but additional energy consumption occurs
Solution Approach 1:
The heating function is merged with the existing intercooler system by using the intercooler's structure to also serve as a heat exchange section. Instead of adding a separate electric heater, the system uses the intercooler's heat transfer capability in reverse, utilizing the temperature difference between incoming and outgoing gas flows to achieve heating without external energy input.
Solution Approach 2:
The system uses its own internal thermal energy to heat the regeneration gas. The intercooler, which normally removes heat from the compressed gas, is utilized to transfer heat from the cooler gas stream to the warmer gas stream, allowing the system to self-regulate temperatures without external energy sources.
3Temperature
If the cooling capacity of the intercooler is reduced to increase regeneration gas temperature, then the temperature of the regeneration gas increases, but moisture builds up in the dryer
Solution Approach 1:
The process is segmented into distinct cooling and heating sections. The intercooler section maintains full cooling capacity to ensure thorough moisture removal, while a separate heating section increases the gas temperature. This segmentation prevents moisture buildup by ensuring cooling and drying functions are not compromised by temperature reduction.
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 solution allows for effective moisture removal and maintains a high regeneration gas temperature without excessive energy consumption, ensuring efficient drying agent regeneration and reduced moisture content in the compressed gas.
Implementation Method 1
a heat exchanger with a primary section located in said pressure line downstream of said intercooler for heating the compressed gas
Implementation Method 2
an intercooler is provided between the compressor elements
Implementation Method 3
a dryer of the type using a drying agent or desiccant for drying the compressed gas
Data Source
Figure 1
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Figure 3
AI summary
Compressor installation with at least two compressor elements (4a, 4b, 4c) wherein the last compressor element (4c) is connected via a pressure line (7) to the penultimate compressor element (4b), wherein an outlet line (8) is connected to the outlet (6) of the last compressor element (4c), wherein an intercooler (9) is provided in the pressure line (7), wherein the compressor installation (1) comprising a dryer (3) for drying the compressed gas, wherein the dryer (3) is provided with a drying section (12) which is connected to the outlet line (8) and with a regeneration section (15), wherein a regeneration line (20) is connected to the inlet (16) of the regeneration section (15), which departs from a branch point (21) of the outlet line (8), characterized in that the compressor installation (1) is provided with a heat exchanger (25) located in said pressure line (7) downstream of said intercooler (9), wherein the compressor installation (1) is provided with means (29) for controlling the heat exchanger (25), wherein the compressor installation (1) is provided with a control unit (31) for controlling the means (29).