High pressure ratio compressors with multiple intercooling and related methods
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Solution Overview
Problem
Conventional turbo-compressor/generator trains with multiple compressors suffer from sub-optimal reliability, high costs, and significant footprint due to the use of two separate compressors and their transition processes, leading to inefficiencies and increased operational expenses.
Innovation Solution
A high pressure ratio compressor with multiple intercooling is used instead of two compressors, featuring a single casing with multiple chambers and impellers, where gas flow is successively compressed and cooled between chambers, allowing for a more efficient, reliable, and cost-effective compression process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If two separate compressors are used to achieve desired compression ratio, then the compression function is distributed, but the system footprint, cost, and reliability are reduced
Solution Approach 1:
The patent combines multiple compression stages into a single integrated compressor unit with a common casing, replacing the conventional arrangement of two separate compressors. This merging eliminates the need for separate housings, foundations, and alignment systems, thereby reducing the overall system footprint while maintaining the required compression ratio through multiple impellers mounted on a single shaft.
Solution Approach 2:
The single compressor unit performs multiple compression functions that were previously distributed across two separate machines. The universal design allows one compressor to accomplish the work of two, providing multi-functionality through staged compression within a single integrated system, thus reducing complexity and space requirements.
2Power
If two separate compressors are used to achieve desired compression ratio, then the compression function is distributed, but the system cost is increased
Solution Approach 1:
By merging multiple compression stages into a single compressor unit, the patent reduces the total number of casings, foundations, and auxiliary systems required. This consolidation lowers manufacturing costs, installation expenses, and maintenance requirements compared to using two separate compressors, while still achieving the desired compression ratio through staged compression.
3Power
If two separate compressors are used to achieve desired compression ratio, then the compression function is distributed, but the system reliability is reduced
Solution Approach 1:
The patent improves reliability by consolidating multiple compression stages into a single integrated unit with a common drive shaft and synchronized impellers. This eliminates the need for inter-compressor transitions and reduces the number of potential failure points, thereby enhancing overall system reliability while maintaining the required compression ratio.
4Temperature
If gas flow is cooled between compression stages, then the gas temperature is reduced, but cooling losses occur
Solution Approach 1:
The patent minimizes cooling losses by reducing the time gas spends in the cooling system between compression stages. The streamlined inter-cooler design and optimized gas flow paths allow rapid cooling, minimizing the duration of heat transfer and reducing energy losses to the environment while still achieving the necessary temperature reduction for the next compression stage.
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 reduces the size, cost, and improves reliability by integrating multiple compressions into a single unit, achieving higher pressure ratios while minimizing cooling losses and operational costs.
Implementation Method 1
A gas flow is successively compressed in each of the chambers
Implementation Method 2
The compressed gas flow is cooled between each compression
Data Source
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AI summary
Turbo-compressor/generator trains 200,300 including high pressure ratio compressors with multiple intercooling and related methods are provided. A high pressure ratio compressor 245,345 with multiple intercooling includes a casing 246, 346 with plural chambers 247,248, one or more shafts 265,365 penetrating inside the chambers, and impellers 257,258 mounted on the one or more shafts inside the chambers, respectively. Each chamber has a gas inlet and a gas outlet to allow gas flow to be input into and to be output from the respective chamber. A gas flow is successively compressed in each of the chambers, and is cooled outside the compressor when transferring from one chamber to a next chamber among the plural chambers.