Gas compression cooling system
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Solution Overview
Problem
Existing multi-stage gas compression systems in natural gas gathering systems are inefficient due to non-variable and wasteful cooling methods, where a single central intercooler provides equal cooling to all stages, expending excess energy and not optimizing thermal energy exchange between each compression stage.
Innovation Solution
An energy-efficient intercooler system with independently controlled intercoolers, each equipped with variable speed fans and temperature sensors, adjusts cooling based on temperature differentials between compression stages, optimizing energy use and efficiency by providing differential thermal energy exchange between stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single central intercooler is used to cool gas between all compression stages, then system manufacturing and maintenance efficiency is improved, but energy consumption increases significantly and cooling cannot be optimized for different stages
Solution Approach 1:
The patent divides the single central intercooler into multiple independent intercoolers, with each intercooler serving a specific compression stage. This segmentation allows each intercooler to be controlled independently based on the specific cooling needs of each stage, preventing energy waste from over-cooling stages that don't require maximum cooling.
Solution Approach 2:
The patent implements variable speed fans in each intercooler that can dynamically adjust their operating speed based on the cooling requirements of each compression stage. This dynamic control allows the system to optimize energy consumption by providing only the necessary cooling at each stage rather than applying uniform maximum cooling across all stages.
2Device complexity
If a single central intercooler provides equal cooling to all compression stages, then system simplicity is maintained, but cooling effectiveness is reduced because the same cooling rate is applied to all stages
Solution Approach 1:
The patent applies local quality by giving each intercooler independent control capabilities tailored to its specific compression stage. Each intercooler can be optimized for the specific thermal characteristics and cooling requirements of its associated stage, improving overall cooling effectiveness compared to a uniform approach.
Solution Approach 2:
The patent incorporates temperature sensors and control systems in each intercooler that continuously monitor the gas temperature and adjust the fan speed accordingly. This feedback mechanism ensures each stage receives the precise cooling it needs, optimizing cooling effectiveness while maintaining reasonable system complexity.
3Ease of operation
If structural elements like louvers are manually adjusted to control cooling, then cooling amount can be controlled, but the intercooler still expends the same amount of energy and wastes cooling capacity
Solution Approach 1:
The patent replaces static manual louver adjustment with dynamic variable speed fan control. The fan speed automatically adjusts based on real-time temperature measurements and cooling requirements, ensuring energy is only expended when and where cooling is actually needed, eliminating the energy waste associated with fixed or manually adjusted systems.
Solution Approach 2:
The patent implements self-service through automatic control systems that monitor temperature and adjust fan operation without manual intervention. The system automatically optimizes its own operation by matching cooling output to actual cooling demands, preventing energy waste from over-cooling while maintaining ease of operation through automated rather than manual control.
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 enhances the efficiency of each compression stage by optimizing cooling, reducing overall energy consumption and maximizing the effectiveness of the gas compression process, allowing for variable and precise thermal energy management between stages.
Implementation Method 1
it is standard to transmit the gas through a centrally positioned intercooler to remove heat from the gas
Implementation Method 2
providing a differentiable and adjustable exchange of thermal energy between each compression stage
Implementation Method 3
Since compression raises the temperature of the gas to the range of 90° F. to 280° F.
Data Source
AI summary
A multi-stage gas compression system useful at the production site and at central collection points, having an energy efficient and effective intercooler system. The system includes a reciprocating compressor having a plurality of compressor valves and cylinders configured in series to provide staged compression to the natural gas. Coupled with the compressor are an inlet port for receiving natural gas to be compressed, and an outlet port for delivering compressed fluid from the compressor to a discharge line, to the transmission pipeline or storage. Facilitating transmission and intercooling of the natural gas between cylinders are a plurality of pipes, each pipe in close proximity with an intercooler. The rate of cooling of the intercooler is determined by a control system coupled therewith, including a temperature sensor positioned within pipe proximal to the intercooler, and means to compare the temperature measured by the temperature sensor and an optimal temperature or temperature range, and determine appropriate levels of cooling provided by the intercooler.