Cooling arrangement and method for cooling an at least two-stage compressed air generator
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Solution Overview
Problem
Existing compressed air generator systems face challenges in efficiently cooling multiple stages of compressors and recovering heat, leading to increased equipment costs and inefficient heat utilization.
Innovation Solution
A cooling arrangement that includes liquid-cooled intercoolers and aftercoolers, along with a subassembly cooler, utilizing a shared coolant circuit with a main cooler and optional heat exchanger for efficient heat recovery and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate cooling systems are used for each compressor stage and subassembly, then each component can be cooled effectively, but the equipment complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple separate cooling systems (intercooler, aftercooler, and subassembly coolers) into a single integrated cooling system with one coolant circuit. This allows all components to be cooled effectively while reducing the number of separate systems, thereby lowering equipment complexity and cost without sacrificing cooling effectiveness.
Solution Approach 2:
The single coolant circuit serves multiple functions by cooling different components at different stages: it cools the intercooler between compression stages, the aftercooler after the final stage, and the subassembly coolers for power electronics and drives. This multi-functional approach eliminates the need for separate dedicated cooling systems for each component.
2Loss of energy
If traditional cooling systems are used, then components can be cooled, but heat recovery is inefficient and equipment costs increase
Solution Approach 1:
The patent converts the waste heat from compressed air and subassemblies into a useful resource by routing all heat-rejecting components through a single coolant circuit. The coolant absorbs heat from multiple sources and delivers it to a heat exchanger where it can be recovered and utilized, transforming previously wasted thermal energy into a beneficial resource while reducing overall system cost.
3Reliability
If multiple separate coolers are installed for each component, then adequate cooling is provided, but the coolant circuit size and overall costs increase
Solution Approach 1:
The patent merges multiple separate cooler systems into a single integrated cooling system where one coolant circuit serves all cooling needs. This consolidation reduces the total amount of coolant required and minimizes the overall size of the coolant circuit while maintaining adequate cooling capacity for all components through strategic placement of heat exchanger sections.
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 enables efficient cooling of multiple compressor stages while reducing equipment costs and enhancing heat recovery, allowing for a significant reduction in the size of the coolant circuit and overall costs.
Implementation Method 1
a liquid-cooled intercooler, which is arranged between a first and a second compressor stage, in order to cool the precompressed air discharged from the first compressor stage
Implementation Method 2
a liquid-cooled aftercooler, which is arranged after the second compressor stage, in order to cool the air compressed by it
Implementation Method 3
a liquid-cooled subassembly cooler is provided, which absorbs heat from further subassemblies of the compressed air generator, in order to cool power electronics or drives and gears of the compressor stages
Implementation Method 4
a main cooler in order to dissipate the heat, which is absorbed by the coolant in the other coolers, out of the compressed air generator
Data Source
AI summary
A cooling arrangement for an at least two-stage compressed air generator comprises an intercooler arranged between a first and a second compressor stage, an aftercooler arranged after the second compressor stage, and a subassembly cooler, which absorbs heat from further subassemblies of the compressed air generator. A coolant circuit comprises a main cooler, the cold side supplying a cooled coolant parallel to the respective coolant inlet of the intercooler, of the aftercooler and of the subassembly cooler, and the hot side receiving the heated coolant exiting in parallel at the respective coolant outlet of the intercooler and of the aftercooler. The coolant outlet of the subassembly cooler is connected to a feed inlet of the intercooler and/or of the aftercooler.