Intercooler Bypass Control for Rotation Dryer Regeneration Temperature

Solution Overview

Problem

Multistage compressor systems face inefficiencies due to excessively high regeneration entry temperatures, which can lead to overheating of downstream components and increased energy consumption, especially when the intake gas is relatively dry, as they require high temperatures for sufficient drying, leading to inefficient compression and potential overheating.

Innovation Solution

A compressor system with a bypass line between next-to-last and last compressors, equipped with a setting element to adjust the regeneration entry temperature, allowing for variable setting based on current conditions such as gas humidity and temperature, ensuring efficient drying while minimizing energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the regeneration entry temperature is increased to ensure sufficient drying, then the drying result is improved, but the compression efficiency deteriorates and downstream components may overheat

Engineering Contradiction:

Improvedrying resultVSAvoidcompression efficiency

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The bypass line with setting element dynamically adjusts the regeneration entry temperature based on operating conditions. When the intake gas is dry, the bypass reduces the temperature to maintain compression efficiency. When humidity increases, the temperature is increased to ensure sufficient drying, thus dynamically adapting to changing conditions rather than maintaining a fixed high temperature

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the regeneration entry temperature parameter according to the humidity level of the intake gas. By using a setting element to control the bypass, the temperature parameter is adjusted to match actual drying needs, avoiding unnecessary high temperatures when the gas is already relatively dry

Inventive Principle:

Principle #35Parameter changes

2Reliability

If the regeneration entry temperature is increased to ensure sufficient drying, then the drying result is improved, but downstream components may overheat

Engineering Contradiction:

Improvedrying resultVSAvoidoverheating of downstream components

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The bypass line with setting element dynamically adjusts the regeneration entry temperature based on operating conditions. When the intake gas is dry, the bypass reduces the temperature to prevent overheating of downstream components. When humidity increases, the temperature is increased to ensure sufficient drying, thus dynamically adapting to changing conditions rather than maintaining a fixed high temperature

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the regeneration entry temperature parameter according to the humidity level of the intake gas. By using a setting element to control the bypass, the temperature parameter is adjusted to match actual drying needs, avoiding unnecessary high temperatures when the gas is already relatively dry

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the regeneration entry temperature is increased to ensure sufficient drying, then the drying result is improved, but energy consumption increases

Engineering Contradiction:

Improvedrying resultVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The bypass line with setting element dynamically adjusts the regeneration entry temperature based on operating conditions. When the intake gas is dry, the bypass reduces the temperature to maintain compression efficiency and reduce energy consumption. When humidity increases, the temperature is increased to ensure sufficient drying, thus dynamically adapting to changing conditions rather than maintaining a fixed high temperature

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the regeneration entry temperature parameter according to the humidity level of the intake gas. By using a setting element to control the bypass, the temperature parameter is adjusted to match actual drying needs, avoiding unnecessary high temperatures when the gas is already relatively dry

Inventive Principle:

Principle #35Parameter changes

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 maintains the desired degree of drying while reducing energy inefficiencies by adjusting the regeneration entry temperature according to specific conditions, avoiding overheating and optimizing the compression process.

Implementation Method 1

the compression heat, which occurs in any case, may be used efficiently for desorption of the water previously adsorbed in the adsorption material of the rotation dryer

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

one or more intercoolers between upstream compressor and last compressor

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 3

a last compressor, which defines the highest compressor stage within the multistage compression

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 4

an adsorption dryer, which is designed as a rotation dryer and comprises a regeneration sector and a drying sector

Methodology Applied

Scientific EffectCentrifugal separation: Centrifugal Separation

Data Source

PatentUS10174972B2Intercooler bypass

Publication Date: 2019.01.08 KAESER KOMPRESSOREN SE

AI summary

A compressor system for compressing gases in a multistage compression includes a next-to-last compressor in a flow direction and a last compressor which are connected in series, one or more intercoolers between the next-to-last compressor and the last compressor, and an adsorption dryer connected downstream of the last compressor and designed as a rotation dryer having a rotating adsorption chamber. An inside of the adsorption chamber includes a regeneration sector and a drying sector. The regeneration sector is connected to the last compressor such that the compressed gas stream output from the last compressor is guided in a full stream principle through the regeneration sector. A bypass line which bypasses the intercoolers is situated between next-to-last compressor and last compressor, and includes a setting element to set the gas stream guided via the bypass line and therefore the regeneration entry temperature of the compressed gas in the regeneration sector appropriately.