Multistage regenerative compressor

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Solution Overview

Problem

Single-stage compressors face issues with high speed requirements for low molecular weight gases, leading to increased temperature, contamination risks, and reduced reliability, especially when processing gases like ammonia, hydrogen, or helium, necessitating expensive ceramic bearings and frequent maintenance.

Innovation Solution

A multi-stage regenerative compressor with magnetic drive coupling and dry bearings, featuring offset impeller stages and gas recirculation, eliminating the need for lubrication and reducing heat generation, while maintaining thermal balance and enhancing reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stress or pressure

If single-stage compressor increases rotation speed to achieve required pressure for low molecular weight gases, then pressure increase is achieved, but temperature increases and thermal balance cannot be maintained

Engineering Contradiction:

Improvepressure increaseVSAvoidtemperature increase

Core Design Contradiction:

Stress or pressureVSTemperature

Solution Approach 1:

The single-stage compression process is divided into multiple stages. Each stage compresses the gas to an intermediate pressure rather than achieving the full pressure increase in one stage. This segmentation reduces the work done per stage, thereby reducing heat generation and allowing thermal balance to be maintained at each stage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements inter-stage cooling where the compressed gas from one stage is cooled before entering the next stage. This periodic cooling action removes heat between stages, preventing cumulative temperature increase and maintaining thermal balance throughout the compression process.

Inventive Principle:

Principle #19Periodic action

2Stress or pressure

If single-stage compressor increases rotation speed to achieve required pressure, then pressure increase is achieved, but contamination risk increases due to grease lubrication

Engineering Contradiction:

Improvepressure increaseVSAvoidcontamination risk

Core Design Contradiction:

Stress or pressureVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical grease lubrication with magnetic coupling for power transmission. The magnetic coupling transmits torque from the motor to the compressor shaft without physical contact, eliminating the need for grease lubrication and thus eliminating the contamination risk to the compressed gas.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The magnetic coupling acts as an intermediary between the motor and the compressor shaft. It transfers energy through magnetic fields rather than direct mechanical contact, allowing the system to operate without lubricants that could contaminate the gas.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stress or pressure

If single-stage compressor increases rotation speed to achieve required pressure, then pressure increase is achieved, but reliability reduces requiring frequent maintenance

Engineering Contradiction:

Improvepressure increaseVSAvoidreliability

Core Design Contradiction:

Stress or pressureVSReliability

Solution Approach 1:

Dividing the compression into multiple stages reduces the rotational speed and mechanical stress required in each stage. This segmentation decreases wear on bearings and other mechanical components, thereby improving reliability and extending maintenance intervals.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Replacing mechanical grease lubrication with magnetic coupling eliminates the need for lubricant replenishment and contamination monitoring. This substitution improves reliability by removing a maintenance-critical component and eliminating contamination risks associated with grease lubrication.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Speed

If single-stage compressor uses ceramic bearings and grease lubrication to operate at high speeds, then high speed operation is achieved, but device complexity and cost increase

Engineering Contradiction:

Improverotation speedVSAvoidbearing complexity

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The patent replaces high-speed mechanical bearings with magnetic coupling for power transmission. This substitution eliminates the need for expensive ceramic bearings and grease lubrication systems, simplifying the device while maintaining the ability to operate at appropriate speeds for multi-stage compression.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 compressor operates efficiently at lower temperatures, reduces contamination risks, and ensures reliable operation without lubrication, making it suitable for processing explosive gases with improved maintenance intervals.

Implementation Method 1

at least one coupling (1) of the magnetic type, connected to said motor (101) and suited to transmit the rotary motion to at least one drive shaft (2)

Methodology Applied

Scientific EffectMagnetic coupling: Magnetism

Data Source

PatentEP4168679B1Multistage regenerative compressor

Publication Date: 2026.04.15 M PUMPS PROCESS SRL

Figure 1
Figure 2~3
Figure 4~4a

AI summary

Compressor (100) of the regenerative type configured to work at pressures exceeding 50 bars, comprising a motor (101), at least one magnetic drive coupling (1) connected to said motor (101) and suited to transmit the rotary motion to at least one drive shaft (2), said drive shaft (2) being mechanically connected to said coupling (1), two impellers (3, 4) of the peripheral type mounted on said shaft (2).