Rotary Screw Compressor Rotors With Internal Cooling Channels
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Solution Overview
Problem
Conventional rotary screw compressors generate excessive heat during the compression process, leading to reduced efficiency, and existing cooling methods in screw compressors are inadequate.
Innovation Solution
The implementation of rotors with internal flow paths for a cooling fluid to absorb heat generated during compression, utilizing counter-flow arrangements and refrigeration subsystems to maintain isothermal efficiency, and the use of additive manufacturing for rotor construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If dry compression is used without coolant introduction, then the compression cell structure is simpler, but the gas temperature increases excessively reducing efficiency
Solution Approach 1:
A cooling fluid is introduced as an intermediary substance that flows through channels in the rotor, acting as a heat transfer medium between the compressed gas and the rotor structure, thereby cooling the gas without direct contact between coolant and compression chamber
Solution Approach 2:
The patent utilizes hydraulic cooling by flowing a liquid coolant through internal channels within the rotor assembly, employing fluid dynamics principles to efficiently remove heat from the compression process
2Temperature
If contact cooling with coolant introduction is used, then the gas temperature is reduced improving efficiency, but the compression cell structure becomes more complex
Solution Approach 1:
The cooling channels are integrated directly into the rotor structure, merging the compression function and cooling function into a single unified component, thereby reducing overall system complexity while maintaining effective cooling
Solution Approach 2:
The rotor serves multiple functions: it performs the primary compression function while simultaneously acting as a heat exchanger through its internal cooling channels, eliminating the need for separate cooling systems
3Temperature
If jacket cooling or internal cooling with hollow rotors is used, then cooling effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs additive manufacturing technology to create complex internal cooling channel geometries within the rotor that would be difficult or impossible to manufacture using traditional machining methods, thereby achieving superior cooling effectiveness without compromising manufacturability
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 reduces temperature increases in the compressed gas, improving compressor efficiency and reducing energy input, while also reducing the compressor's mass and manufacturing complexity.
Implementation Method 1
rotors having flow paths for a cooling fluid formed therethrough to enable cooling of the rotors
Implementation Method 2
the cooling fluid is heated by the rotors
Data Source
AI summary
A gas compressor is disclosed that includes a first rotor having a first rotor body, the first rotor body including a plurality of helical lobes, an internal volume within the first rotor body defined by a wall, and a turbine disposed within the internal volume, the turbine including a turbine body and a plurality of airfoils extending substantially radially from the turbine body to the wall, where the internal volume is structured to enable a cooling fluid to flow therethrough. The gas compressor further includes a second rotor body including a plurality of helical flutes, an inlet manifold and an outlet manifold, both disposed within the second rotor body, and a body channel within at least one flute extending from and in fluid communication with the inlet manifold to the outlet manifold, where the body channel is structured to enable a cooling fluid to flow therethrough.