Method and apparatus for compressing a gas
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Solution Overview
Problem
Existing gas compression systems inefficiently utilize refrigerant fluid circuits for cooling and heat recovery, leading to suboptimal energy performance and increased energy expenditure.
Innovation Solution
A single refrigerant fluid circuit is used to cool a two-stage compressor, with one flow cooling the intermediate stage and another flow cooling the final stage, resulting in different temperature rises, with the hotter flow providing heat to a heat-consuming element and mixing with the cooler flow for efficient energy management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water is sent in parallel to both intercooler and aftercooler to cool the compressor, then both coolers are cooled effectively, but the temperature of heated water becomes too high for efficient heat recovery utilization
Solution Approach 1:
The single water flow from the cooling system is segmented into two separate flows: a first flow directed to the intercooler and a second flow directed to the aftercooler. This segmentation allows each flow to be optimized for its specific cooling function, with the first flow experiencing a larger temperature rise suitable for heat recovery, while the second flow experiences a smaller temperature rise for effective aftercooler cooling.
Solution Approach 2:
Different temperature characteristics are assigned to different water flows based on their specific functions. The first flow (to intercooler) is designed to undergo a temperature rise of 50-80°C to provide efficient heat recovery, while the second flow (to aftercooler) undergoes a temperature rise of 10-30°C to ensure effective cooling of the compressed gas after compression.
2Device complexity
If a single refrigerant fluid circuit is used for both intercooler and aftercooler cooling, then the system is simplified, but the temperature management becomes less efficient
Solution Approach 1:
The single refrigerant fluid circuit is segmented into two separate flow paths within the same circuit system. The first flow path directs refrigerant to the intercooler with a controlled temperature rise of 50-80°C for heat recovery, while the second flow path directs refrigerant to the aftercooler with a controlled temperature rise of 10-30°C for effective cooling, thus maintaining circuit simplicity while improving temperature management efficiency.
3Loss of energy
If water flow is divided with different temperature rises for heat recovery and cooling functions, then energy efficiency is improved, but the system requires precise flow control
Solution Approach 1:
The system controls the temperature rise parameter for each water flow to optimize energy efficiency. The first flow (to intercooler) is controlled to have a temperature rise of 50-80°C to maximize heat recovery efficiency, while the second flow (to aftercooler) is controlled to have a temperature rise of 10-30°C to ensure adequate cooling performance. These parameter ranges are designed to balance energy efficiency with operational simplicity.
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
Improves overall energy balance by optimizing compressor performance and heat recovery, reducing energy consumption while maintaining effective cooling.
Implementation Method 1
an intermediate cooler (R1) for cooling the gas downstream of the intermediate or first compression stage and a final cooler (R2) for cooling the gas downstream of the final compression stage
Implementation Method 2
the first heated flow is sent at least occasionally to supply heat to a heat-consuming element
Implementation Method 3
the second heated flow, which has not been sent to supply heat to the heat-consuming element and has not been cooled, is mixed with the first flow at least occasionally cooled
Data Source
Figure 1
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Figure 3
AI summary
In a method for compressing a gas (G), the gas is compressed in a compressor having an intermediate stage and a final stage, an intermediate cooler (R1) for cooling the gas downstream of the intermediate stage and a final cooler (R2) for cooling the gas downstream of the final compression stage, a refrigerant fluid, coming from a source (B) is divided into a first flow and a second flow, the first flow (21) is sent to cool the intermediate cooler and the second flow (11) is sent to cool the final cooler, the first and second reheated flows being at different temperatures, the first reheated flow is sent to supply heat to an element (A) producing a first cooled flow and the second reheated flow is mixed with the first cooled flow and the mixture (2) is sent to the source.