Multi-Compressor SEC Modeling for Energy-Efficient Operation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for optimizing multiple compressor systems face challenges due to lack of detailed design or performance data from manufacturers, leading to inefficiencies and difficulties in optimizing energy consumption, especially in systems with mixed brands and types of compressors.
Innovation Solution
A method involving constructing ideal specific energy consumption curves for individual and combined compressors, creating a theoretical operation model, and comparing measured energy consumption with calculated curves to identify optimal compressor combinations and operating conditions, accounting for factors like intake air temperature and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If detailed design or performance data from manufacturers is obtained, then manufacturing precision and optimization accuracy improve, but device complexity and data processing requirements increase
Solution Approach 1:
The patent segments the complex task of system optimization into individual compressor evaluations. Each compressor is assessed separately using its own performance curve, and then results are aggregated to determine optimal system configuration. This divides the complex data processing into manageable units that can be handled independently.
Solution Approach 2:
The patent transforms detailed manufacturer performance data into simplified performance curves that represent key operational characteristics. By converting complex raw data into standardized curve representations, the system maintains optimization accuracy while reducing data processing complexity.
2Productivity
If compression ratio and operating pressure are increased, then productivity improves, but energy consumption increases
Solution Approach 1:
The patent implements dynamic optimization by continuously adjusting compressor operating points based on real-time system conditions and demand. Rather than operating at fixed high compression ratios, the system dynamically selects optimal operating points that balance productivity requirements with energy efficiency, allowing compression ratios to vary according to actual needs.
Solution Approach 2:
The patent changes operational parameters (compression ratio, speed, pressure) to optimize the balance between productivity and energy consumption. By adjusting these parameters based on performance curves and system conditions, the system achieves high output flow while minimizing energy use through optimal parameter selection.
3Reliability
If compressors are operated far from surge conditions, then reliability improves, but the range of available operating points decreases
Solution Approach 1:
The patent uses dynamic optimization to operate compressors close to their optimal efficiency points while maintaining a safety margin from surge conditions. The system continuously adjusts operating parameters to stay within reliable operating zones while maximizing the usable range of operating points through real-time adaptation to changing conditions.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention describes a method for gauging energy used for producing a unit of mass or volume of compressed gas (Specific Energy Consumption) in relation to a common output flow in a multiple compressor system, said method comprising: - from a first compressor, constructing an ideal specific energy consumption curve in the first compressor as a function of the output flow of the first compressor; and - from a first compressor and a second compressor, constructing a combined ideal specific energy consumption specific energy consumption curve in the first compressor and the second compressor as a function of the combined output flow of the first compressor and the second compressor, wherein the method involves constructing one or several ideal specific energy consumption curve(s) for multiple combined compressors, in any combination(s), and wherein the method involves creating a theoretical operation model for the multiple compressor system.