Intercooler Bypass Control for Compressor Dryer Regeneration Heat
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Solution Overview
Problem
Multi-stage compressor systems face inefficiencies due to high regeneration inlet temperatures, which can lead to excessive heat in downstream components and increased energy consumption, especially when the gas is already relatively dry, necessitating a more efficient control of the regeneration inlet temperature to maintain dryness while optimizing energy use.
Innovation Solution
A compressor system with a bypass line and adjusting element between intercoolers allows for variable adjustment of the regeneration inlet temperature based on the gas's dryness and operational conditions, ensuring a fixed degree of dryness with lower energy expenditure by routing part of the gas flow through the bypass line to adjust the temperature before it enters the regeneration sector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the regeneration inlet temperature is increased to ensure sufficient drying, then the dryness of the compressed gas is improved, but the energy consumption of the compression process increases
Solution Approach 1:
The patent applies dynamics by making the regeneration inlet temperature variable rather than fixed. The temperature is dynamically adjusted based on the actual dryness requirements of the compressed gas, allowing the system to adapt to changing operating conditions and avoid unnecessary energy consumption while maintaining sufficient drying.
Solution Approach 2:
The patent changes the parameter of regeneration inlet temperature from a fixed high value to a variable value that can be adjusted according to the actual dryness needs. This parameter change allows the system to optimize the balance between drying effectiveness and energy consumption by matching the temperature to the actual requirements.
2Reliability
If the regeneration inlet temperature is increased to ensure sufficient drying, then the dryness of the compressed gas is improved, but the temperature of downstream components becomes excessively high
Solution Approach 1:
The patent applies dynamics by making the regeneration inlet temperature variable rather than fixed. The temperature is dynamically adjusted based on the actual dryness requirements of the compressed gas, allowing the system to adapt to changing operating conditions and avoid unnecessary energy consumption while maintaining sufficient drying.
Solution Approach 2:
The patent changes the parameter of regeneration inlet temperature from a fixed high value to a variable value that can be adjusted according to the actual dryness needs. This parameter change allows the system to optimize the balance between drying effectiveness and energy consumption by matching the temperature to the actual requirements.
3Use of energy by moving object
If the regeneration inlet temperature is decreased to improve energy efficiency, then the energy consumption is reduced, but the dryness of the compressed gas becomes insufficient
Solution Approach 1:
The patent applies feedback by monitoring the actual dryness of the compressed gas and using this information to adjust the regeneration inlet temperature. The control device receives information about the dryness state and automatically adjusts the temperature to maintain sufficient drying while optimizing energy consumption, preventing both overheating and insufficient drying.
Solution Approach 2:
The patent applies dynamics by making the regeneration inlet temperature variable rather than fixed. The temperature is dynamically adjusted based on the actual dryness requirements of the compressed gas, allowing the system to adapt to changing operating conditions and avoid unnecessary energy consumption while maintaining sufficient drying.
4Ease of operation
If the regeneration inlet temperature is regulated to a fixed value to maintain consistent drying, then the dryness control is simplified, but the energy efficiency decreases when the gas is already relatively dry
Solution Approach 1:
The patent applies feedback by monitoring the actual dryness of the compressed gas and using this information to adjust the regeneration inlet temperature. The control device receives information about the dryness state and automatically adjusts the temperature to maintain sufficient drying while optimizing energy consumption, preventing both overheating and insufficient drying.
Solution Approach 2:
The patent applies dynamics by making the regeneration inlet temperature variable rather than fixed. The temperature is dynamically adjusted based on the actual dryness requirements of the compressed gas, allowing the system to adapt to changing operating conditions and avoid unnecessary energy consumption while maintaining sufficient drying.
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 approach enhances energy efficiency by maintaining the specified degree of dryness while reducing overall energy consumption and avoiding unnecessary overheating, as the regeneration inlet temperature is set dynamically according to the gas's humidity and operational parameters.
Implementation Method 1
the heat of compression that is already generated can be used efficiently to desorb the water previously adsorbed in the adsorption material of the rotary dryer
Implementation Method 2
one or more intercoolers between the upstream compressor and the last compressor
Implementation Method 3
several compressors connected in series, namely an upstream compressor and a last compressor which defines the highest compressor stage
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The invention relates to a compressor system for compressing gases in a multi-stage compression, comprising a plurality of compressors (11, 12) connected in series, comprising at least one compressor (11) which is the penultimate one in the direction of flow and a last compressor (12) which, within the multi-stage compression, highest compressor stage, one or more intermediate coolers (13) between the penultimate compressor (11) and the last compressor (12) and an adsorption dryer (16) downstream of the last compressor (12), which is designed as a rotary dryer with a rotating adsorption chamber (44) and inside the adsorption chamber comprises a regeneration sector (17) and a drying sector (18), the regeneration sector (17) being connected to the last compressor (12) in such a way that the compressed gas flow discharged from the last compressor (12) flows through the Regeneration sector (17) of the adsorption dryer (16 ) is routed, with a bypass line (14) bridging the or at least one intermediate cooler (13) being arranged between the penultimate compressor (11) and the last compressor (12), in which an adjusting member (15) is provided to (14) to be able to adjust the guided gas flow and thus the regeneration inlet temperature TRi of the compressed gas in the regeneration sector (17) as required.