Open-Crankcase Compressor Gas Purity via Recycle Loop
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Solution Overview
Problem
Open-crankcase reciprocating compressors face contamination issues due to the introduction of ambient air, which compromises the purity of compressed gas, especially in applications requiring high purity, leading to inefficiencies and reduced performance.
Innovation Solution
A compressed gas recycle control loop is implemented to reduce the vacuum inside the compressor, preventing ambient air from entering during the compression process by recycling high-pressure gas back to the inlet, thus maintaining gas purity and extending the service life of the compressor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an open-crankcase reciprocating compressor is used, then the compressor is economical and reliable for low-cost applications, but the compressed gas becomes contaminated with ambient air due to piston seal leakage
Solution Approach 1:
A piston rod seal is introduced as an intermediary barrier between the crankcase ambient air and the compression cylinder. This seal prevents ambient air from entering the cylinder through the piston rod clearance, thereby maintaining gas purity while preserving the economical open-crankcase design.
Solution Approach 2:
The patent creates a sealed environment around the piston rod by introducing a piston rod seal, effectively isolating the compression cylinder from the ambient air in the crankcase. This prevents contamination of the compressed gas with ambient air molecules.
2Ease of manufacture
If a simple polymer piston seal is used in an open-crankcase compressor, then the compressor is economical, but the piston seal leaks after a few hundred hours of operation, allowing ambient air to enter the cylinder
Solution Approach 1:
A piston rod seal is introduced as an intermediary barrier between the crankcase ambient air and the compression cylinder. This seal prevents ambient air from entering the cylinder through the piston rod clearance, thereby maintaining gas purity while preserving the economical open-crankcase design.
Solution Approach 2:
The piston rod seal is installed in advance to prevent ambient air leakage before it can contaminate the compressed gas. This proactive sealing measure ensures long-term reliability and maintains gas purity throughout the compressor's operational life.
3Object-affected harmful factors
If additional barriers such as labyrinth compressors are used to prevent gas leakage, then gas purity is maintained, but the device complexity and acquisition cost significantly increase
Solution Approach 1:
A single piston rod seal is introduced as an intermediary barrier between the crankcase ambient air and the compression cylinder. This seal prevents ambient air from entering the cylinder through the piston rod clearance, thereby maintaining gas purity while preserving the economical open-crankcase design.
Solution Approach 2:
The patent extracts the sealing function from the complex piston assembly and implements it separately through a dedicated piston rod seal. This simplifies the overall design by isolating the sealing requirement to a single component rather than requiring complex multi-barrier systems.
4Duration of action of stationary object
If the compressor operates with worn piston seals, then the compressor continues to operate at low cost, but ambient air is pulled into the cylinder during the suction stroke, contaminating the compressed gas
Solution Approach 1:
A piston rod seal is introduced as an intermediary barrier between the crankcase ambient air and the compression cylinder. This seal prevents ambient air from entering the cylinder through the piston rod clearance, thereby maintaining gas purity while preserving the economical open-crankcase design.
Solution Approach 2:
The piston rod seal is installed in advance to prevent ambient air leakage before it can contaminate the compressed gas. This proactive sealing measure ensures long-term reliability and maintains gas purity throughout the compressor's operational life.
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
This solution effectively reduces gas temperature rise, prolongs compressor service life, and maintains high gas purity even as piston seals wear, making economical oil-less compressors suitable for purity-sensitive applications.
Implementation Method 1
reduce the magnitude of vacuum inside the open-crankcase compressor relative to ambient air pressure
Implementation Method 2
employs a compressed gas recycle control loop to reduce the magnitude of vacuum inside the open-crankcase compressor
Implementation Method 3
compresses gas to a higher pressure produced at its outlet
Implementation Method 4
reduces gas temperature rise
Implementation Method 5
reduces gas temperature rise
Data Source
AI summary
An apparatus and method for substantially reducing or eliminating the introduction of ambient air into an open-crankcase compressor is disclosed. The method employs a compressed gas recycle control loop to reduce the magnitude of vacuum inside the open-crankcase compressor relative to ambient air pressure, thereby reducing or eliminating the introduction of ambient air into the open-crankcase compressor during the gas compression process.