Regulatable Intercooler for Multistage Compressor
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Solution Overview
Problem
Oil-injected multistage compressor devices face inefficiencies due to limited cooling capabilities and the risk of condensate formation, which complicates maintenance and increases costs, while traditional multistage devices are complex and costly.
Innovation Solution
An oil-injected multistage compressor device with a regulatable intercooler between compressor stages, equipped with a heat pump and adjustable cooling mechanisms, ensures the gas inlet temperature remains above the dew point, preventing condensate formation and maximizing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a regulatable intercooler is provided between compressor stages to cool the gas, then cooling efficiency is improved and temperature drop is increased, but the risk of condensate formation increases and device complexity increases
Solution Approach 1:
The intercooler is made regulatable with adjustable cooling capacity, allowing the system to dynamically adapt cooling intensity to operating conditions. This prevents over-cooling that would cause condensate while maximizing efficiency when safe to do so.
Solution Approach 2:
The system changes the temperature parameter dynamically by regulating the intercooler based on real-time conditions. The regulatable design allows optimization of the temperature parameter to achieve maximum cooling efficiency while maintaining it above the dew point to prevent condensate.
2Temperature
If oil is injected between compressor stages to cool the gas, then cooling is achieved, but extra oil is added to the gas which is not always desirable and cooling efficiency is limited
Solution Approach 1:
The harmful element (oil) is extracted from the cooling function. Instead of using oil injection for cooling, the patent employs a separate intercooler system that provides cooling without adding oil to the gas stream, thus eliminating the unwanted side effect while maintaining the beneficial cooling effect.
Solution Approach 2:
An intermediary cooling system (intercooler) is introduced between the compressor stages to perform the cooling function without directly mixing the cooling medium with the gas. This intermediary approach achieves cooling efficiency while preventing oil contamination of the compressed gas.
3Temperature
If an intercooler is used to actively extract heat from compressed gas, then cooling efficiency is improved, but pressure drop increases causing efficiency loss and condensate formation risk increases
Solution Approach 1:
The intercooler's cooling capacity is made regulatable rather than fixed, allowing the system to optimize the balance between cooling effectiveness and pressure drop. The regulation mechanism adjusts cooling intensity to achieve maximum temperature reduction while minimizing pressure loss and avoiding excessive cooling that would cause condensate.
Solution Approach 2:
The system applies partial cooling action rather than maximum cooling at all times. By regulating the intercooler to provide just sufficient cooling to maintain efficiency without over-cooling, the system avoids the harmful effects of excessive cooling (condensate formation) while still achieving the benefits of improved cooling efficiency.
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
This configuration achieves significant temperature drops and efficiency gains, reducing the risk of condensate and enhancing performance beyond traditional compressor devices without cooling or oil curtain injection.
Implementation Method 1
an intercooler is provided between the first and second compressor elements, whereby the intercooler will actively extract heat from the compressed gas after the first compression stage
Implementation Method 2
the temperature at the gas inlet of the high-pressure stage compressor element can be regulated so that it is above the dew point
Implementation Method 3
the temperature of the air or the water can be changed by using a bypass conduit and/or by screening off part of the intercooler
Data Source
AI summary
Oil-injected multistage compressor device including a low-pressure compressor element (2) with a gas inlet (4a) for gas to be compressed and a gas outlet (5a) for low-pressure compressed gas and a high-pressure stage compressor element (3) with a gas inlet (4b) for low-pressure compressed gas and a gas outlet (5b) for high-pressure compressed gas. The gas outlet (5a) of element (2) is connected to inlet (4b) of element (3) via a conduit (6). The conduit (6) has a regulatable intercooler (9) configured to regulate the temperature at the gas inlet (4b) of the high-pressure stage compressor element (3) so that it is above the dew point. The intercooler (9) includes a regulatable air cooler and/or a regulatable water cooler, and is configured to adjust the temperature of the air or water by using a bypass conduit (16) and/or by screening off part of the intercooler (9).