Compressor Dryer Return-Line Heat Exchanger Using the Oil Circuit
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Solution Overview
Problem
Existing compressor installations face inefficiencies with air-cooled and water-cooled regeneration gas coolers, leading to increased size and complexity, and dependency on external water supply, respectively, while posing risks of oil or water leakage into compressed gas.
Innovation Solution
Utilizing the compressor's oil circuit to cool regeneration gas through an oil-cooled heat exchanger, integrated within the oil circuit, eliminating the need for additional coolers and external cooling sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If an air-cooled cooler is used to cool the regeneration gas, then the system is simpler and does not depend on external water supply, but many additional conduits are required and the device becomes more extensive
Solution Approach 1:
The invention merges the regeneration gas cooling function with the existing oil circuit by incorporating a heat exchanger into it. This eliminates the need for separate air-cooled cooler conduits and integrates the cooling function into the already-present oil circulation system, thereby reducing device complexity and space requirements.
Solution Approach 2:
The oil circuit is given a dual function: it continues to lubricate and cool the compressor element while also serving as the cooling medium for the regeneration gas through the integrated heat exchanger. This multi-functionality eliminates the need for dedicated cooling conduits for regeneration gas.
2Temperature
If a water-cooled cooler is used to cool the regeneration gas, then the cooling efficiency is improved, but the system becomes dependent on external water supply which must be provided by the user
Solution Approach 1:
The system uses its own internal oil circuit as the cooling medium for the regeneration gas, eliminating dependency on external water supply. The oil, which is already circulating through the compressor element for lubrication and cooling, is utilized to cool the regeneration gas through the integrated heat exchanger, making the system self-sufficient.
Solution Approach 2:
The oil circuit serves multiple functions simultaneously: lubricating the compressor element, cooling the compressor element, and now also cooling the regeneration gas. This eliminates the need for separate water supply infrastructure while maintaining effective cooling.
3Power
If the regeneration gas is cooled by ambient air through grouped coolers, then the cooling capacity is sufficient, but the coolers must be dimensioned larger as they receive partially heated ambient air
Solution Approach 1:
The invention combines the regeneration gas cooling function with the compressor element cooling function by using the same oil circuit for both purposes. The oil, cooled by the compressor element, then cools the regeneration gas in the heat exchanger, creating a cascaded cooling system that improves overall cooling efficiency without requiring larger cooler dimensions.
Solution Approach 2:
The oil is first used to cool the compressor element, and then this pre-cooled oil is used to cool the regeneration gas. This preliminary cooling action of the oil before it reaches the heat exchanger improves the cooling efficiency for the regeneration gas without requiring additional cooling capacity or larger dimensions.
4Productivity
If the regeneration air temperature is high to effectively regenerate the drying agent, then the regeneration process is improved, but the oil in the heat exchanger may be exposed to temperatures that adversely affect its life
Solution Approach 1:
The oil acts as an intermediary cooling medium between the regeneration gas and the system components. The oil absorbs heat from the regeneration gas in the heat exchanger, preventing direct exposure of other components to high temperatures. The oil's continuous circulation and cooling capacity protect it from thermal degradation while enabling effective regeneration.
Solution Approach 2:
The oil circulates continuously through the system, constantly being cooled by the compressor element and then used to cool the regeneration gas. This continuous circulation prevents the oil from being exposed to sustained high temperatures that would degrade it, while maintaining effective regeneration through continuous heat exchange.
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 results in a more compact design, reduces dependency on external cooling, minimizes the risk of oil or water leakage, and maintains efficient operation without compromising dryer performance.
Implementation Method 1
a primary portion of a heat exchanger is incorporated into the return line for cooling the regeneration gas, wherein the secondary portion of the heat exchanger is incorporated into the oil circuit of the compressor element
Implementation Method 2
the dryer is of the type that uses a drying agent or desiccant
Data Source
Figure 1
AI summary
Compressor installation (1) with a compressor element (2), with an outlet (9) with an outlet line (8), and with a dryer (2), that is provided with a drying section (14) and a regeneration section (15), wherein the drying section (14) is provided with a first inlet (16a) and a first outlet (16b), wherein the first inlet (16a) is connected to the outlet line (8), wherein the regeneration section (15) is provided with a second inlet (17a) and a second outlet (17b), wherein a regeneration line (18) is provided between the second inlet (17a) and a first point (19) of the outlet line (8), wherein at the second outlet (17b) a return line (20) is connected that connects the second outlet (17b) to a second point (21) on the outlet line (8) downstream of the first point (19), characterized in that, in the return line (20), a primary portion (27) of a heat exchanger (28) is incorporated, wherein a secondary portion (29) of the heat exchanger (28) is incorporated in an oil circuit (10) of the compressor element.