Oil-Injected Compressor Control After Oil Separator Cooling
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Solution Overview
Problem
Existing compressor devices control the temperature of compressed gas at the outlet of the compressor element to prevent condensate formation, but this approach is inadequate as the temperature drops below the dew point downstream of the oil separator, leading to condensate formation and inefficiencies.
Innovation Solution
A control system that measures the temperature of the compressed gas at the outlet and downstream of the oil separator, using feed-forward or master-slave control to adjust the cooling means to maintain the temperature above the dew point, ensuring stable and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the temperature is set sufficiently high above the dew point (typically 20°C) to prevent condensate formation, then condensate formation is avoided, but the lifetime of the oil decreases and efficiency is reduced
Solution Approach 1:
The control system dynamically adjusts the temperature parameter based on actual measurements from both outlet and downstream sensors, rather than maintaining a fixed high temperature margin. This allows the system to operate at lower temperatures (reducing oil degradation) while still preventing condensate formation through real-time compensation for temperature drops.
Solution Approach 2:
The system transitions from static temperature control to dynamic control, continuously adjusting temperature based on real-time measurements from multiple locations. This dynamic approach allows the system to maintain the minimum necessary temperature margin to prevent condensate while minimizing unnecessary heating that would reduce oil lifetime and efficiency.
2Ease of operation
If control is based only on temperature at the outlet, then outlet temperature is controlled, but control effectiveness is delayed and instabilities occur downstream
Solution Approach 1:
The control system divides the temperature monitoring function into separate measurement points at the outlet and downstream of the oil separator. This segmentation allows independent measurement and control of temperature at different locations, enabling more precise and stable control by addressing temperature variations in different zones separately rather than using a single control point.
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 solution effectively prevents condensate formation and maintains optimal oil temperature, enhancing compressor efficiency and longevity by controlling the temperature accurately downstream of the oil separator.
Implementation Method 1
a cooler (16) which can be bypassed by means of a bypass line (17)
Implementation Method 2
a controlled mixing valve (18) with an inlet (19) and two outlets (20a, 20b), the mixing valve (18) having its inlet (19) and one of the two outlets (20a) connected to the injection line (10) and the other outlet (20b) connected to the bypass line (17)
Implementation Method 3
the temperature of the gas after the oil separator will drop, so that it will get below the dew point and thus condensate can occur
Data Source
AI summary
Compressor device comprising an oil-injected compressor element (2) with an outlet (4) connected via an outlet line (8) to an oil separator (9) which is connected via an injection pipe (10) to the compressor element (2), wherein controllable cooling means (15) for the oil are provided, the compressor device (1) being provided with a control unit (21) and thereto connected measuring means (22a, 22b) for controlling the cooling means (15) to control a temperature (T_uit_afsch) downstream of the oil separator (9), the measuring means (22a, 22b) including means (22a) for determining a temperature (T_uit) at the outlet (4) and a temperature sensor (22b) for determining the temperature (T_uit_afsch) downstream of the oil separator (9), the control unit (21) including a controller (25) for controlling the cooling means (15) on the basis of signals from said measuring means (22a, 22b) and on the basis of a dew point.