Gear-Integrated Screw Expander for Compressor Heat Recovery
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Solution Overview
Problem
Multi-stage compressors face inefficiencies in energy usage due to the lack of effective methods to harness and utilize the heat of compression for power reduction.
Innovation Solution
A gear-driven compressor system incorporating a screw expander that utilizes the heat of compression to generate steam, which imparts rotational energy back into the system, reducing the power required to drive the compressor stages and enhancing overall efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a single prime mover drives multi-stage compressors using a gear box, then the compressor system can operate with a single power source, but the heat of compression is wasted and energy efficiency is reduced
Solution Approach 1:
The patent converts the waste heat from compression into useful work by feeding it to a steam generator, which produces steam to drive a turbine that powers the compressors. This transforms the harmful energy loss into a beneficial power source, directly resolving the contradiction between energy efficiency and heat waste.
Solution Approach 2:
The system changes the thermal state parameters of the compression heat by directing it through a steam generator to produce high-temperature steam. This parameter transformation enables the heat to be utilized in a different form (thermal energy to mechanical energy via turbine), thereby improving overall energy efficiency.
2Use of energy by moving object
If compression heat is utilized to power the compressors, then energy efficiency is improved, but the system complexity increases due to additional components
Solution Approach 1:
The patent merges the compression system with a steam generation and turbine system into an integrated power recovery system. By combining these functions, the waste heat from compression is directly utilized to generate power, improving efficiency while the integrated design manages the added complexity through functional consolidation.
Solution Approach 2:
The gear box is designed with multiple drive outputs that can accommodate both the compressors and the turbine, making it a multi-functional component. This universality allows the same mechanical transmission system to handle both compression driving and power recovery, reducing the need for separate dedicated systems and managing complexity.
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 reduces energy consumption and improves efficiency by leveraging the heat of compression to power the expander, thereby optimizing the operation of multi-stage compressors.
Implementation Method 1
A gear-driven compressor system incorporating a screw expander that utilizes the heat of compression to generate steam
Implementation Method 2
utilizes the heat of compression to generate steam
Implementation Method 3
steam, which imparts rotational energy back into the system
Data Source
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AI summary
A compressor system includes a gear box having a first drive gear, a second drive gear and a first driven gear. A prime mover is coupled to the first drive gear and is operable to input rotational power to the gear box and a compressor is coupled to the first driven gear and is operable in response to rotation of the first driven gear to produce a flow of compressed gas. A heat exchanger is positioned to receive the flow of compressed gas and a flow of fluid and is operable to cool the flow of compressed gas and heat the flow of fluid to produce a flow of heated gas. A screw expander is coupled to the second drive gear and is operable in response to the flow of heated gas to input rotational power to the gear box.