Dual-Action Piston Vacuum System Using Steam Condensation
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Solution Overview
Problem
Current vacuum generation and storage systems face challenges in scalability, energy efficiency, and cost due to reliance on electricity and large vacuum pumps, with issues like steam loss and non-condensable gas residues affecting vacuum levels and increasing energy and infrastructure costs.
Innovation Solution
A dual-action piston-cylinder system using wall-imbedded cooling and atomized spray cooling to efficiently generate and store vacuum by alternating steam insertion and condensation between two chambers, minimizing steam loss and leveraging low-grade thermal energy for cost-effective operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steam is inserted into the condensation chamber to reduce pressure, then vacuum level is improved, but steam condenses prematurely during mixing with gas and non-condensable gas residues remain
Solution Approach 1:
The system divides the condensation chamber into two separate chambers (first condensation chamber and second condensation chamber) that are spatially separated by a partition wall. This segmentation prevents mixing between steam and gas in different chambers, eliminating premature condensation and non-condensable gas residues while maintaining effective vacuum levels.
Solution Approach 2:
The invention extracts and removes non-condensable gas residues from the condensation chamber by providing a dedicated exhaust pathway. The system separates the condensation process from the gas removal process, allowing steam to condense completely while extracted gases are removed through separate channels, preventing residue accumulation.
2Productivity
If large vacuum pumps are used to generate sufficient removal flowrate, then vacuum generation capability is improved, but energy consumption and infrastructure costs increase
Solution Approach 1:
The system utilizes phase transition of steam (vapor to liquid condensation) to generate vacuum. By injecting steam into the condensation chamber and allowing it to condense on cooled surfaces, the system creates pressure differential that drives gas removal. This phase change mechanism eliminates the need for energy-intensive mechanical vacuum pumps.
Solution Approach 2:
The invention replaces mechanical vacuum pumps with a thermal field-based system. Instead of using mechanical force to create vacuum, the system uses temperature differential and phase transition of steam to generate the necessary pressure differential for gas removal, significantly reducing energy consumption and infrastructure requirements.
3Productivity
If steam is used to flush gas out of the condensation chamber, then gas removal is improved, but steam mixes with gas and is flushed out as a mixture causing steam loss
Solution Approach 1:
The system segments the condensation chamber into separate regions (first and second condensation chambers) with distinct functions. One chamber is dedicated to steam condensation while the other handles gas removal. This spatial separation prevents steam from mixing with gas during the flushing process, eliminating steam loss while maintaining effective gas removal.
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 system achieves significant cost savings and improved energy efficiency by ensuring complete steam filling and reducing non-condensable gas residues, enabling scalable and economically viable vacuum generation and storage with reduced energy consumption.
Implementation Method 1
wall-imbedded heat exchangers or similar heat transfer devices
Implementation Method 2
condensing the first quantity of steam in the first chamber
Implementation Method 3
atomized spray cooling from cylinder ends
Implementation Method 4
condensing the first quantity of steam in the first chamber
Implementation Method 5
pressure difference between the inserted steam in the first chamber and gas in the second chamber
Implementation Method 6
compresses content of chamber B and increases pressure inside chamber B
Implementation Method 7
condensing the first quantity of steam in the first chamber
Implementation Method 8
condensing the first quantity of steam in the first chamber by wall cooling
Data Source
AI summary
A vacuum generation system and method utilizes a dual-action piston-cylinder vacuum generation system to evacuate a vacuum storage. Saturated steam of higher than ambient pressure is inserted into a condensation cylinder with two chambers separated by a movable piston. Steam moves the piston to fill one chamber while expel gaseous content and condensate out of the other chamber. Steam is then condensed to a rough vacuum (RV) state by cooling. By repeated operations of inserting and condensing steam in each chamber alternatively, a sustained vacuum generation is achieved. A multi-level vacuum storage is also disclosed with a high vacuum (HV) storage placed inside a rough vacuum (RV) storage to reduce leakage as well as mechanical stresses. The vacuum generation system and method is extended for creating a prime mover or actuator to drive vacuum pumps maximizing thermal energy usage for increased vacuuming capacity.