High-Throughput Diaphragm Compressor With Staged Modules
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Solution Overview
Problem
Conventional diaphragm compressors are limited by physical constraints such as compressor head volume, speed of operation, actuation force, and material strength, which hinder their ability to achieve high-pressure and high-throughput applications.
Innovation Solution
A diaphragm compressor system with multiple compressor modules stacked in a configuration, featuring a clamping mechanism to apply force to compressor heads and a hydraulic drive with variable-pressure supply to intensify work oil, allowing for sequential stages of increasing pressurization and dynamic clamping to accommodate thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional diaphragm compressor design is used, then structural simplicity is maintained, but high-pressure and high-throughput performance cannot be achieved
Solution Approach 1:
The compressor system is divided into multiple compressor modules (first compressor module, second compressor module, etc.) that can be stacked in series. Each module contains its own compressor head and diaphragm assembly, allowing the system to achieve high throughput and pressure by combining multiple smaller units rather than relying on a single large complex unit.
2Stress or pressure
If single-stage compression is used, then system simplicity is maintained, but high-pressure output (up to 800 bar) cannot be achieved
Solution Approach 1:
The compression process is segmented into multiple stages, with each compressor module performing one stage of compression. The first compressor module compresses gas to an intermediate pressure, then the second compressor module further compresses it to the final high pressure (up to 800 bar). This staged approach achieves high pressure output while keeping each individual module relatively simple.
3Stability of the object's composition
If rigid clamping is used to hold compressor modules, then structural stability is maintained, but thermal expansion cannot be accommodated
Solution Approach 1:
The clamping mechanism incorporates dynamic elements that allow for thermal expansion of the compressor modules during operation. The clamps maintain sufficient holding force to ensure structural stability and proper alignment, while simultaneously allowing the modules to expand and contract with temperature changes without causing structural damage or misalignment.
4Reliability
If constant clamping force is applied to compressor heads, then sealing is maintained, but hydraulic efficiency decreases due to thermal expansion
Solution Approach 1:
The clamping mechanism uses dynamic clamping force that can adjust to thermal expansion of the compressor heads during operation. This maintains adequate sealing integrity to prevent leaks while accommodating thermal expansion, thereby preserving hydraulic efficiency by reducing the energy loss that would occur with rigid constant clamping.
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 achieves high-pressure and high-throughput gas pressurization, with modules capable of outputting pressures up to 800 bar, addressing limitations of conventional compressors and enhancing reliability and hydraulic efficiency.
Implementation Method 1
The hydraulic drive is configured to pressurize work oil and provide the pressurized work oil to the first and second compressor heads. During a discharge cycle of a compressor head, the hydraulic power unit is configured to drive the respective diaphragm piston toward the corresponding diaphragm compressor head, intensifying the work oil in the respective variable volume region to an intensified pressure, and actuating the diaphragm to the second position.
Implementation Method 2
The diaphragm is configured to actuate from a first position to a second position during a discharge cycle to pressurize process gas in the process gas region from an inlet pressure to a discharge pressure
Implementation Method 3
The clamping mechanism is configured to increase a distance between the base plate and the end plate in response to thermal expansion of one or more compressor modules of the plurality of compressor modules
Data Source
AI summary
Devices and methods for operating a diaphragm compressor system provide high output pressure and high throughput. In some embodiments, modular diaphragm compressors are stacked with a clamping mechanism pressing the compressor modules together. In embodiments, multiple stacks are provided as stages of a pressurization process. In embodiments, a main stage valve controls one or more pressure circuits for one or more hydraulic actuators of compressor modules. In embodiments, orifices configured for damping are incorporated to control actuator piston movement within a compressor module.