The system and the method for recovery of waste heat energy contained in oil in an oil-cooled air compressor
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Solution Overview
Problem
Existing systems for recovering waste heat from oil-cooled industrial gas compressors face inefficiencies due to the location of the heat exchanger in the long oil circuit, leading to heat emission into the atmosphere and risks of oil overcooling and steam condensation.
Innovation Solution
A system where the heat exchanger is strategically placed between the oil separator and the compressor's three-way valve, allowing for efficient waste heat recovery by bypassing the main cooler and incorporating temperature sensors for control, thereby preventing condensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the heat exchanger is located in the long oil circuit downstream of the thermostatic valve, then the oil cooling function is maintained, but heat is emitted into the atmosphere and oil overcooling with steam condensation risk occurs
Solution Approach 1:
The heat exchanger is positioned upstream of the thermostatic valve in the oil circuit, allowing heat recovery to occur before the oil reaches the compression chamber. This preliminary heat extraction prevents the oil from being overcooled and causes steam condensation, while still maintaining adequate cooling function. The thermostatic valve then regulates the oil temperature to ensure it remains within safe operating ranges.
Solution Approach 2:
The thermostatic valve acts as an intermediary device between the heat exchanger and the oil compression chamber. It receives oil from the heat exchanger and regulates its flow to maintain appropriate temperature, preventing both overcooling and steam condensation while allowing efficient heat recovery to occur in the heat exchanger.
2Productivity
If the heat exchanger is placed to maximize heat recovery, then waste heat recovery efficiency increases, but the risk of oil overcooling and steam condensation increases
Solution Approach 1:
The system incorporates a thermostatic valve that provides feedback control on oil temperature. The valve monitors the oil temperature after heat extraction and automatically adjusts the oil flow to maintain stable temperature within safe operating ranges. This feedback mechanism ensures high heat recovery rates while preventing oil overcooling and steam condensation.
Solution Approach 2:
The system dynamically adjusts oil flow parameters through the thermostatic valve to optimize heat recovery while maintaining temperature stability. By changing flow rate, pressure, and temperature parameters in real-time, the system achieves maximum heat extraction efficiency without compromising oil temperature control or causing steam condensation.
3Reliability
If temperature measurement and control systems are added to prevent oil overcooling, then oil temperature control reliability improves, but device complexity increases
Solution Approach 1:
The thermostatic valve is a self-regulating device that automatically maintains oil temperature within safe ranges without requiring external control systems. It uses the oil's own thermal properties to open or close passages based on temperature differential, providing inherent temperature control that improves reliability while adding minimal complexity to the 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
This configuration maximizes waste heat recovery, reduces heat emission to the atmosphere, and ensures the compressor operates within safe temperature ranges, enhancing energy recovery efficiency and simplifying the heat recovery system.
Implementation Method 1
a heat exchanger between the oil and the receiving medium (e.g. water) for recovering waste heat energy contained in the oil
Implementation Method 2
an oil separator for separating oil from the compressed gas supplied from the compressor main body
Data Source
AI summary
A system for the recovery of waste heat energy contained in oil in an oil-cooled air compressor, characterised in that the outlet of the oil side of the oil separator (4) is connected to the inlet of the oil side of the heat exchanger (9), and the outlet of the oil side of the heat exchanger is connected to the oil flow divider (10). A method for the recovery of waste heat energy contained in oil in oil-cooled air compressors consists in diverting the receiving medium flow away from the heat exchanger (9) by means of a control device (12), or stopping the receiving medium flow when at least the temperature of the oil returning to the compressor main body (2) is lower than the setpoint or the temperature of the oil entering the heat exchanger (9) is lower than the temperature of the receiving medium.