Compressor Leak Emissions Quantification Using Engine Oxygen Sensors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Gas processing systems face challenges in accurately measuring and mitigating leakage emissions from gas compressors, which contribute to environmental pollution and resource loss, due to the high cost and limited availability of suitable flow meters.
Innovation Solution
A system that captures leakage emissions from gas compressors and directs them to the engine as an alternate fuel source, using oxygen sensor data to adjust the air-fuel ratio and quantify emissions through closed-loop error corrections without flow meters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If flow meters are used to measure leakage emissions from gas compressors, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses the engine's exhaust system and oxygen sensors as an intermediary measurement platform. Instead of directly measuring compressor leakage emissions with specialized flow meters, the system routes emissions through the engine and uses the existing exhaust gas analysis infrastructure to indirectly quantify the leakage amount by comparing air-fuel ratio deviations, thereby avoiding complex dedicated measurement devices
Solution Approach 2:
The engine itself serves as the measurement instrument. By monitoring the engine's own air-fuel ratio using its integrated oxygen sensors and comparing it against expected values when leakage emissions are present versus absent, the system enables the engine to self-diagnose and quantify compressor leakage emissions without external measurement equipment
2Measurement precision
If flow meters are used to measure leakage emissions, then measurement precision is improved, but cost increases
Solution Approach 1:
The system makes the engine serve multiple functions: it acts as both the primary driver for gas compression and as a measurement instrument for detecting compressor leakage emissions. By utilizing the engine's existing fuel system, oxygen sensors, and control electronics for dual purposes, the patent eliminates the need for separate expensive flow metering equipment
Solution Approach 2:
The patent employs inexpensive oxygen sensors that are already standard components in engine systems, replacing expensive specialized flow meters. The approach uses readily available, low-cost sensing technology to achieve precise emissions measurement, significantly reducing system cost
3Loss of substance
If leakage emissions are directed to the engine as fuel source, then loss of substance is reduced, but measurement and quantification of emissions becomes more difficult
Solution Approach 1:
The system implements a feedback mechanism where oxygen sensors continuously monitor the air-fuel ratio in the engine exhaust, and the control system compares actual readings against expected values. When leakage emissions are present, the feedback loop detects the deviation and quantifies the amount of leakage by calculating the difference between commanded and actual air-fuel ratios, enabling precise measurement despite the emissions being routed to the engine
Solution Approach 2:
The patent separates the measurement function from the fuel utilization function by using distinct pathways: leakage emissions are routed to the engine through emissions lines for energy recovery, while a separate sensing and control system independently monitors and quantifies the emissions by analyzing air-fuel ratio deviations, allowing both mitigation and measurement to occur simultaneously without interference
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
Accurately measures and mitigates leakage emissions, providing diagnostics on compressor health and triggering notifications for excessive leaks, thus reducing environmental impact and resource loss.
Implementation Method 1
The oxygen sensor data is generated by one or more oxygen sensors arranged to detect oxygen levels in the exhaust stream
Implementation Method 2
The engine is configured to drive a gas compressor... configured to ingest fuel from a fuel source... exhaust stream of the engine
Data Source
AI summary
A gas processing system comprises a compressor, an engine configured to drive the compressor, and a control system with emissions quantification capabilities. In some examples, one or more emissions lines direct leakage emissions from the compressor to the engine to be ingested as an alternate fuel source. One or more oxygen sensors generate oxygen sensor data indicating oxygen levels in an exhaust stream of the engine. The control system determines an actual air-fuel ratio of the exhaust stream based at least in part on the oxygen sensor data. The control system determines an error correction corresponding to an adjustment in the air-fuel mixture supplied to the engine to compensate for a difference between the actual air-fuel ratio and a commanded stoichiometric air-fuel ratio. The control system quantifies the leakage emissions from the compressor based at least in part on a comparison of the error correction to a baseline error correction.