Multi-Stage Gas Delivery with Series Compression and Cooling
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Solution Overview
Problem
Existing gas supply devices face challenges in increasing pressure and volumetric flow rate without exceeding temperature thresholds, leading to unsuitable gas for downstream applications and potential damage to components.
Innovation Solution
A multi-stage pressurized gas delivery system utilizing two gas supply devices connected in parallel or series modes, controlled by a control valve and driven by separate drivers, with temperature and pressure sensors to manage heat and pressure, and optional coolers to maintain optimal conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a single-stage compressor is used to increase gas pressure to high levels (exceeding 30+ psig), then the pressure output is improved, but the temperature of the gas increases beyond acceptable thresholds
Solution Approach 1:
The compression process is divided into multiple stages. The system uses a first gas supply device (e.g., first compressor) and a second gas supply device (e.g., second compressor) connected in series, where the first device compresses gas to an intermediate pressure and the second device further compresses it to the final high pressure. This segmentation allows temperature management between stages and prevents excessive temperature rise that would occur in a single-stage compression to the same final pressure.
2Stress or pressure
If gas pressure is increased to meet downstream application requirements, then the pressure output is improved, but the gas temperature increases rendering it unsuitable for downstream applications
Solution Approach 1:
The multi-stage compression system with intermediate cooling allows temperature control at each stage. The first compressor raises pressure to an intermediate level, then a cooler reduces the temperature before the gas enters the second compressor. This ensures the final high-pressure gas does not have excessively high temperature that would harm downstream components.
Solution Approach 2:
A cooler is introduced as an intermediary component between the first and second gas supply devices. This cooler acts as a mediator that removes excess heat from the compressed gas, allowing the system to achieve high pressure output while maintaining acceptable temperature levels for downstream applications.
3Device complexity
If a single gas supply device is used to meet high pressure and flow rate demands, then the system simplicity is maintained, but the temperature control and component protection are insufficient
Solution Approach 1:
The system is segmented into multiple gas supply devices and associated coolers, each handling a portion of the compression and cooling task. This segmentation distributes the thermal load and mechanical stress across multiple components, preventing any single component from experiencing excessive thermal fatigue and improving overall system reliability.
4Productivity
If parallel mode operation is used to increase volumetric output, then the flow rate is improved, but the pressure output may be insufficient for high-pressure applications
Solution Approach 1:
The system dynamically switches between parallel and series configurations of the gas supply devices based on the required output conditions. When high volumetric flow rate is needed, the devices operate in parallel mode. When high pressure is needed, they operate in series mode. This dynamic reconfiguration allows the system to meet varying demand requirements for both flow rate and pressure.
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 effectively increases pressure and flow rate while managing temperature, ensuring suitable gas output for downstream applications and preventing component damage.
Implementation Method 1
pressurizing air via a single-stage compressor to achieve a high-pressure output (exceeding 30+ psig) may undesirably increase the temperature of the air beyond an acceptable threshold
Implementation Method 2
with temperature and pressure sensors to manage heat and pressure, and optional coolers to maintain optimal conditions
Data Source
AI summary
A pressurized gas delivery system includes at least a first gas supply source and a second gas supply source. The first gas supply source is configured to supply a first pressurized gas output, and the second gas supply source is configured to supply a second pressurized gas output. A valve including at least a first position and a second position fluidly connects an outlet of the first gas supply source to a system outlet in the first position and to an inlet of the second gas supply source in the second position.