Gas Separation Membrane Control for Purity and Energy Efficiency
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Solution Overview
Problem
Existing gas separation devices face challenges in maintaining product gas purity and efficiency due to high operating pressures, complex compressor control, and inefficiencies in energy use, particularly when product gas flow is below design capacity or exceeds it, leading to hazardous situations and increased costs.
Innovation Solution
A device with a source for pressurized gas supply, a membrane unit, and control systems that adjust the flow and pressure based on target values for both permeate and retentate gases, using a retentate control system and pressure sensors to maintain desired purity and reduce energy consumption, compatible with various compressor types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the operating pressure is increased to reduce total operation cost, then energy efficiency improves, but product gas purity control becomes difficult and hazardous situations may arise
Solution Approach 1:
The patent implements a feedback control system where a purity sensor continuously measures the actual purity of the product gas and compares it to a target purity value. The control unit adjusts the operating pressure based on this feedback, increasing pressure when purity is too low and decreasing it when purity exceeds the target, thereby maintaining reliable purity control while operating at high pressures for energy efficiency
Solution Approach 2:
The system dynamically changes the operating pressure parameter based on real-time purity measurements. By adjusting pressure as a controllable parameter in response to purity deviations, the system achieves both high energy efficiency (through elevated operating pressures) and reliable purity control (through parameter adjustment)
2Reliability
If a speed controlled compressor is used to adjust compressor speed based on product gas purity, then purity control improves, but the solution is limited to specific compressor types and may cause premature failure
Solution Approach 1:
The patent employs a universal control approach that works with any compressor type equipped with a control connection, not just speed-controlled compressors. The control unit can adjust various compressor parameters (speed, inlet valve position, unload/loading states) to achieve purity control, making the solution adaptable to reciprocating compressors, screw compressors, centrifugal compressors, and other types
Solution Approach 2:
The system uses feedback from purity sensors to continuously adjust compressor operation. The control unit receives purity measurements and automatically modifies compressor settings to maintain target purity, providing reliable control across different compressor types without requiring type-specific control mechanisms
3Productivity
If the compressor operates at full capacity, then productivity is maximized, but energy is wasted when product gas flow is less than design flow
Solution Approach 1:
The system dynamically adjusts the compressor operating point based on actual product gas flow requirements and purity measurements. Rather than operating at fixed full capacity, the compressor speed or loading is continuously optimized to match demand, maximizing productivity when flow is high and reducing energy consumption when flow is low
Solution Approach 2:
The control unit changes compressor operating parameters (speed, pressure ratio, loading) in response to varying product gas flow demands. When product gas flow is below design capacity, the system reduces compression parameters accordingly, maintaining productivity at required levels while avoiding energy waste from excessive compression
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
Ensures consistent product gas purity, reduces energy and feed gas usage, prevents over-pressurization, and allows for self-compensation for membrane aging and fouling, while being adaptable to different compressor types and operating conditions.
Implementation Method 1
a membrane installation with selective membranes, i.e. membranes that have a different permeability for different gases based on the properties of these gases
Data Source
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AI summary
A device for separating gases comprises the following components: a source for the gases and flow adjustment means; a membrane unit for the production of a permeate gas and a retentate gas, one of which is the product gas; purity determining means for the product gas; a first control unit for the device; a retentate control system and a product gas pressure measurement, whereby the source has a second control unit for the flow adjustment means as a function of a target value of the gases and the first control unit is connected to the second control unit and to the retentate control system, whereby the first control unit can determine the target value and can control the retentate control system.