Compressor device and a cooler thereby used

Abstract

A compressor device with at least two compressor elements connected in series and at least two coolers of which there at least two split coolers that are split in separate successive stages, respectively a hot stage and a cold stage, that are connected together in one or more separate cooling circuits such that the compressed gas is cooled sufficiently between the compressor elements with a minimum coolant flow rate to keep the temperature of the cooled gas at the outlet of each cooler below a maximum permissible value and thereby to realize a desired temperature increase of the coolant in at least one of the aforementioned cooling circuits.

Claims

1. A compressor device for compressing gas in two or more stages, wherein the compressor device comprises: at least two compressor elements connected in series; and at least two coolers for cooling the compressed gas, wherein each cooler is provided with a primary section through which the compressed gas to be cooled is guided and a secondary section that is in heat-exchanging contact with the primary section and through which coolant is guided, wherein at least two of the coolers are split coolers whose secondary section is split into at least two separate stages to cool the gas that is guided through the primary section in successive stages, respectively at least a hot stage for a first cooling of the compressed gas that flows into the primary section of the coolers and a cold stage for the further cooling of the compressed gas, wherein the stages of the secondary sections of the coolers are connected together in one or more separate cooling circuits such that the compressed gas between the compressor elements is cooled, with a minimum coolant flow rate through the cooling circuits, to keep the temperature of the compressed gas at the outlet of each cooler below a maximum permissible value and thereby having a predetermined temperature increase of the coolant in at least one of the cooling circuits, wherein at least two of the cold stages of the secondary sections of the coolers are connected together in series in a cooling circuit through which a coolant is guided, wherein the coolant in the cooling circuit is first guided through the cold stages and then through the hot stages.

2. The compressor device according to claim 1, wherein the predetermined temperature increase is about 30 C.

3. The compressor device according to claim 1, wherein at least two of the hot stages of the secondary sections of the coolers are connected together in series in a cooling circuit through which a coolant is guided.

4. The compressor device according to claim 3, wherein the coolant is lastly guided through the hot stage of the cooler immediately following the compressor element which has a highest outlet temperature.

5. The compressor device according to claim 1, wherein at least two of the cold stages of the secondary sections of the coolers and at least two of the hot stages of the secondary sections of the coolers are connected together in series in a cooling circuit through which a coolant is guided, whereby the coolant in this cooling circuit is first guided through the cold stages and then through the hot stages.

6. The compressor device according to claim 5, wherein all stages of the secondary sections of the coolers are connected together in series in one single cooling circuit with one single coolant, whereby the coolant in this cooling circuit is first guided through the cold stages and then through the hot stages.

7. The compressor device according to claim 1, wherein all stages of the secondary sections of the coolers are connected together in one single cooling circuit with one single coolant, whereby at least two cold stages are connected together in parallel.

8. The compressor device according to claim 1, wherein at least two cold stages, that are connected together in series, are incorporated in a first cooling circuit, and that any additional cold stages are connected in series or in parallel and are incorporated in a second cooling circuit that is separated from the first cooling circuit.

9. The compressor device according to claim 1, wherein at least two of the cold stages of the secondary sections of the coolers are connected together in parallel in a first cooling circuit, and any additional cold stages of the secondary sections of the coolers are connected together in series or in parallel in a second cooling circuit that is separated from the first cooling circuit.

10. The compressor device according to claim 1, wherein at least two of the cold stages are connected together in parallel and at least one cold stage is connected in series in a first cooling circuit, and any additional cold stages of the secondary sections of the coolers are connected together in series or in parallel in a second cooling circuit that is separated from the first cooling circuit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) With the intention of better showing the characteristics of the invention, a few preferred embodiments of a compressor device according to the invention and a cooler applicable therewith are described hereinafter by way of an example, without any limiting nature, with reference to the accompanying drawings, wherein:

(2) FIG. 1 schematically shows a compressor device according to the state of the art;

(3) FIGS. 2 and 3 show a diagram of two variants of split coolers according to the invention;

(4) FIG. 4 shows a diagram such as that of FIG. 1, but for a compressor device according to the invention with coolers such as those of FIG. 2;

(5) FIG. 5 shows a variant of FIG. 4;

(6) FIG. 6 shows a typical characteristic curve of a compressor element as used in FIG. 4;

(7) FIGS. 7 to 9 show different variants of a compressor device according to the invention;

(8) FIG. 10 shows a cross-section of a practical embodiment of a cooler according to the invention such as that of FIG. 2;

(9) FIG. 11 shows a cross-section according to line XI-XI in FIG. 10;

(10) FIG. 12 shows a perspective view of a cover that is indicated by F12 in FIG. 10;

(11) FIG. 13 shows a view according to arrow F13 in FIG. 12;

(12) FIG. 14 shows a variant configuration of the cooler of FIG. 10;

(13) FIG. 15 shows a practical embodiment of a cooler block with three coolers according to FIG. 10 and FIG. 14 connected together.

DETAILED DESCRIPTION OF THE INVENTION

(14) FIG. 1 shows a conventional compressor device 1 according to the state of the art with three compressor elements 2, respectively 2a, 2b and 2c, which are connected together in series between an inlet 4 and an outlet 5 by means of pipes 3.

(15) Downstream from each compressor element 2 there is a cooler for cooling the compressed gas, respectively an intercooler 6a between the compressor elements 2a and 2b, an intercooler 6b between the compressor elements 2b and 2c, and an aftercooler 6c after the last compressor element 2c.

(16) The intercoolers 6a and 6b are thereby intended to cool to a maximum the temperature of the compressed gas from a previous compressor element 2 before being drawn in by a subsequent compressor element 2, and this is to ensure that the efficiency of the compression in the compressor is optimum.

(17) The aftercooler 6c ensures cooling of the compressed gas before it leaves the compressor device 1 according to the invention via the outlet 5, and this to prevent damage to the connected consumers.

(18) Each cooler 6 is provided with a primary section 7 through which the compressed gas to be cooled is guided, as shown by the arrows A, and a secondary section 8 that is in heat-exchanging contact with the primary section 7 and through which the coolant is guided in the opposite direction, as shown by the arrows B.

(19) The compressor device 1 is provided with a single cooling circuit 9 with an input 10 and an output 11.

(20) With the conventional compressor device of FIG. 1 the coolant is guided through the cooling circuit 9 in parallel through the secondary sections 8 of the coolers 6, whereby the coolant supply is thus distributed over the three coolers 6 and whereby each cooler 6 thus receives coolant with the same input temperature.

(21) The cooling circuit 9 is calculated to realise a maximum compression efficiency with maximum cooling in each intercooler 6a and 6b. With a conventional compressor device typically one or more heat-exchanging components are connected to the cooling circuit, such as an oil cooler or a connection to a cooling circuit of a motor. Generally their share of the total heat-exchanging capacity of the cooling circuit is relatively small.

(22) A disadvantage of such a device is that the maximum cooling also requires a high available flow rate of the coolant and thus associated high investment costs, operating costs and maintenance costs of the cooling circuit 9.

(23) Another characteristic is that the temperature of the coolant at the output 11 is relatively low and consequently difficult to use for other applications or for recovering energy therefrom.

(24) A cooling circuit according to the invention differs from the parallel connection described above and makes use of split coolers 12, as shown in FIGS. 2 and 3.

(25) The split cooler 12 according to FIG. 2 comprises a primary section 13, just as with a conventional cooler 6, with an input 14 and output 15 for compressed gas, and a secondary section 16, which in this case, contrary to a conventional cooler 6, is split into two separate stages 16 and 16, each with a separate input 17 and output 18 to drive a coolant through it in the opposite direction to the compressed gas, in the direction of the arrows C and C.

(26) In this way the cooling of the compressed gas by the coolant is split into two successive stages 16 and 16, i.e. a hot stage 16 for a first cooling of the hot gas that flows into the primary section 13 via the input 14, and a cold stage 16 for further cooling the gas before this further cooled gas leaves the primary section 13 via the output 15.

(27) An alternative of a split cooler 12 is shown in FIG. 3, whereby in this case the cooler 12 is split into two subcoolers 12 and 12, whereby in this case the primary section 13 is also split into two stages 13 and 13 that are connected together in series to form one continuous primary section as it were.

(28) The compressor device 19 according to the invention shown in FIG. 4 differs from the conventional device 1 of FIG. 1 by the single coolers 16 being replaced by split coolers 12 such as those of FIG. 2, whereby the secondary sections 16 and 16 are incorporated into one single cooling circuit 20 with an input 21 and output 22 for the coolant.

(29) The cooling circuit 20 is designed such that the coolant is guided in series successively through all stages 16 and 16 of the secondary sections 16 of the coolers 12 in a certain order that is a function of the configuration of the compressor device 19 and the intended purpose.

(30) In the case of FIG. 4 the coolant is first guided through the cold stages 16 of the coolers 12 in the same order with respect to the flow of the gas, whereby in other words the coolant is first driven through the intercooler 12a and then in order through the second intercooler 12b and aftercooler 12c.

(31) Then the coolant is guided successively through the hot stages 16, this time in the reverse order to the order in which the gas flows through the coolers 12, thus first through the aftercooler 12c, then through the second intercooler 12b, and then through the first intercooler 12a.

(32) In this way it is ensured that all coolers 12 cool sufficiently to keep the temperature of the cooled gas at the output 15 of each cooler 12 below the imposed maximum value that takes account of a minimum control margin and the occurrence of possible damaging consequences for example for the downstream section of the compressor device if this maximum temperature is exceeded, without necessarily being concerned with optimising the efficiency of the compressor device 19.

(33) In other words higher temperatures of the gas that is drawn in by the compressor elements 2b and 2c are allowed than would be required for an optimum efficiency of these compressor elements 2b and 2c.

(34) This enables lower coolant flow rates to be provided than in the case of a conventional compressor device 1 such as that of FIG. 1, which benefits the cost and complexity of the cooling circuit 20.

(35) Moreover, in this way a higher temperature increase of the coolant can also be realised between the input 21 and the output 22 of the cooling circuit 20. As a result heat can be recovered more efficiently than in the case of a conventional compressor device 1.

(36) By design the cooling circuit can be dimensioned for example, such that a desired temperature increase of the coolant is obtained that is of the order of magnitude of 30 C., better still at least of the order of magnitude of 40 C., or preferably even greater than 50 C. depending on the desire of the user in order to be able to utilise hot cooling water for example.

(37) Preferably the coolant is first guided through the cold stage 16 of the cooler 12 immediately prior to the compressor element 2, which by design needs the lowest inlet temperature. In the example of FIG. 4 this is the second compressor element 2b and the immediately preceding intercooler 12a.

(38) This criterion for determining the order in which the coolant is driven through the coolers 12 also applies to every combination of two stages. This means that in the case of FIG. 4 the coolant is then guided through the stage 16 of the cooler 12b immediately prior to the compressor element 2c with the second lowest desired inlet temperature, etc.

(39) After going through the cold stages 16 then preferably the coolant is lastly guided through the hot stage 16 of the cooler 12 immediately following the compressor element 2, which by design has the highest outlet temperature. In the case of the example of FIG. 4 this is the cooler 12a and the compressor element 2a.

(40) As a result of this choice the highest temperature at the output 22 of the cooling circuit 20 is obtained.

(41) FIG. 5 shows another configuration of a compressor device according to the invention, whereby in this case by design the compressor element 2c needs the lowest inlet temperature, and whereby by design the second compressor element 2b has a higher outlet temperature than the first compressor element 2a, thus the reverse situation of FIG. 4.

(42) Making use of the same criteria as for FIG. 4 to determine the order in which the coolant is guided through the stages 16 and 16 in series, in the case of FIG. 5 the chosen order is reversed with regard to the coolers 12a and 12b.

(43) Other serial connections are thus possible depending on the different outlet temperatures and desired inlet temperatures of the separate compressor elements 2 in the design phase. It goes without saying that the order of the cooling water flow through two coolers 12 is freely chosen if the desired inlet temperatures and/or outlet temperatures are comparable.

(44) Another criterion that can be used for determining the order in which the stages 16 and 16 are connected together in series is based on the risk that a certain compressor element 2 will pump, which can manifest itself in turbocompressors as a phenomenon that occurs above a certain temperature threshold of the gas at the inlet, and whereby the gas flow can oscillate and even flow backwards, coupled with severe vibrations and the risk of damage and an increased temperature rise in the compressor element 2.

(45) On the characteristic curve of a turbocompressor, an example of which is shown in FIG. 6, this phenomenon is expressed as a surge line 23 that determines the maximum permissible inlet temperature tmax as a function of the flow rate through the compressor element for a given inlet pressure and pressure ratio across the compressor element 2.

(46) At a certain gas flow rate corresponding to a certain flow rate QA, by design a certain operating point A will be obtained at a temperature tA at the outlet of the cooler 12 located immediately upstream.

(47) The smaller the distance between the operating point A and the surge line 23, the greater the risk of the occurrence of the harmful pumping effect.

(48) In this case the criterion can be employed to first guide the coolant through the cold stage 16 of this cooler 12, in which by design the temperature of the compressed gas at the outlet 15 of the cooler 12 concerned is the closest to the maximum permissible surge temperature at the inlet of the compressor stage 2 immediately following it, or in other words through the cold stage 16 of the cooler 12 prior to the compressor element 2 with the greatest risk of surge.

(49) If a serial connection as set out above turns out to be inadequate for sufficient cooling between two compressor elements 2, or if aftercooling or if the pressure drop along the cooling water side is too great, if need be it can be chosen to connect two or more cold stages 16 and two or more hot stages 16 in parallel to one another, as is the case in the example of FIG. 7, in which the coolant is first driven in parallel through at least 2 cold stages 16 in one single cooling circuit 20 before going through the remaining cold stages 16 in series. Analogously, for reasons of pressure drop, it can be chosen to drive the cooling water in parallel through at least two hot stages 16 and in series through the remaining hot stages 16.

(50) As the minimisation of the costs of the cooling circuit becomes less important, it can also be chosen by design to select two separate cooling circuits 20 and 20 as shown in FIG. 8, with the same coolant or otherwise, whereby at least two cold stages 16 in the cooling circuit 20 are connected together in series or entirely or partially in parallel and at least two hot stages 16 in the cooling circuit 20 are connected together in series or entirely or partially in parallel, whereby the order of serial connection can be determined by making use of the same criteria as in the case of FIG. 4. Here too it can be chosen to drive the cooling water in parallel through at least 2 of the cold stages 16 and in series through the remaining cold stages 16. The same for the hot stages 16.

(51) In this way the cooling circuit 20 can be optimised in relation to sufficient cooling for the purpose of obtaining the best possible compression efficiency and the greatest possible operating range of the compressor, and the cooling circuit 20 can be geared to obtaining the highest possible temperature rise of the coolant, for the purpose of maximum heat recovery for example.

(52) As the aftercooler 12c does not generally contribute to the efficiency of the compressor device 19, alternatively a separate cooling circuit 20 can be chosen in which the cold stages 16 of the intercoolers upstream from the compression stages 2 in series or entirely or partially in parallel are provided with a first coolant and in which the remaining stages 16 and 16 of the aftercooler and the hot stages 16 of the intercooler are connected together in series or entirely or partially in parallel such that the cooling water of the cooling circuit 20 lastly flows through the hot stage of this cooler that is located downstream from the compression stage with the highest outlet temperature, referring to FIG. 9.

(53) It is clear that in the example of FIG. 9 the aftercooler 12c can also be replaced by a conventional single cooler 6, just as could be the case for the aftercooler 12c of FIGS. 4, 5 and 7.

(54) FIG. 10 shows a practical embodiment of the cooler 24 that has a modular composition in such a way that it is alternatively configurable as a split cooler 12 or as a non-split single cooler 6.

(55) In this case the cooler 24 is constructed as a tube cooler with a tube bundle 25 with a series of tubes 26 to guide a coolant through it to form the secondary section of the cooler 24, whereby this tube bundle 25 is affixed in a housing with a shell 27 that is closed off at the ends of the tubes 26 by endplates 28 through which the tubes 26 protrude by their ends.

(56) The shell 27 is provided with an input 14 and an output 15 for a gas to be cooled, whereby the housing forms a channel that guides the gas over and around the tubes 26 to form the primary section 13 of the cooler 24.

(57) The tubes 26 are grouped into two series of subbundles 25 and 25, as can be seen in the cross-section of FIG. 11, that are located at a distance L from one another.

(58) The tube bundle 25 is covered at it ends by a cover 29, respectively 30, whereby in this case these covers are identical and provided with partitions 31 that divide the cover 29 and 30 into compartments 32 that cover over one or more ends of the tubes 26 to channel a coolant through these tubes 26.

(59) In the example shown in FIG. 10, these partitions 31 are straight parallel partitions that are provided with a seat 33 in which a seal 34 can be affixed between the partition 31 concerned and an aforementioned endplate 28 to separate the flows in the mutual compartments 32.

(60) In the configuration of FIG. 10 in which a seal 34 is provided in all partitions 31, two of the partitions 31 form a separating partition 31 in each of the covers 29 and 30, whereby this separating partition 31 in each cover 29 and 30 forms a separation between the subbundles 25 and 25 and whereby in this case the seals 34 are affixed between such a separating partition 31 and the central section 35 of an endplate 28 between the subbundles 25 and 25.

(61) In the example shown in FIG. 10, the covers 29 and 30 are provided with an input 17, respectively 17, and an output 18, respectively 18, for a coolant, whereby this input and output of each cover are both located on the same side of an aforementioned separating partition 31.

(62) In the configuration of FIG. 10 the covers 29 and 30 are affixed such that the input 17 and output 18 of one cover 29 are provided opposite one subbundle 25 to channel a coolant through one of these subbundles 25 as shown by the arrows C, while the input 17 and output 18 of the other cover 30 are provided opposite the other subbundle 25 to channel the same or a different coolant through this other subbundle 25 as shown by the arrows C.

(63) Both channels are separated from one another by the separating partitions 31, such that in the configuration of FIG. 10 the cooler 24 in fact forms a split cooler 12 with one primary section with an input 14 and output 15 for the gas to be cooled, and a secondary section with two separate channels with an input 17, respectively 17, and an output 18, respectively 18, for a coolant, for the purpose of being able to cool the gas in the primary section in two stages.

(64) Preferably the top subbundle 25 forms the hot stage 16 that is in contact with hot gas supplied from a compressor element 2, while the bottom subbundle 25 forms the cold stage 16 that is in contact with colder gas that has already been partly cooled in the hot stage 16.

(65) FIG. 14 shows the same cooler as that of FIG. 11, but in the configuration of a single, non-split cooler.

(66) To this end the seals 34 in the separating partitions 31 are omitted and an input 17 and an output 18 is closed off with a plug 36 or similar, so that only one input 17 and one output 18 remain to channel one single coolant through both subbundles 25 and 25, as shown by the arrows C.

(67) It is hereby clear that at the location of the separating partitions 31, due to the absence of the seals 34 in these partitions 31, there is an internal connection between the channel of the coolant in the bottom subbundle 25 and the channel of the coolant in the top subbundle 25, so that one continuous channel is formed as it were between the input 17 and the output 18 without external interconnection.

(68) Alternatively it would of course be possible, starting with the split configuration of FIG. 10, to leave the seals 34 at the location of the separating partitions 31 in place and to connect the output 18 externally to the input 17 in order to convert the cooler 24 of FIG. 10 to a non-split cooler.

(69) Incidentally, it is absolutely not necessary to use two identical covers 29 and 30, but one cover 29 can be provided with all necessary inputs and outputs for example, while the other cover 30 is completely closed.

(70) Another possibility is that one of the covers 29 or 30 is provided with two inputs and the other cover is provided with two outputs, for example with a cooler with 6 rows of tubes.

(71) It is also possible to work without separate seals 34 and to make the partitions 31, 31 fit closely to the endplates 28. By entirely or partially machining away the separating partitions 31, the configuration of a single non-split cooler is obtained again.

(72) FIG. 15 illustrates how a cooler block with two intercoolers 12a and 12b and one aftercooler 6c, for example, can be realised in a simple way with one type of cooler, whereby the intercoolers 12a and 12b are configured as split coolers and the aftercooler 6c is configured as a non-split cooler, whereby the coolant is first guided in series through the cold parts 16 and then driven in series through the hot parts 16 in an order that can be determined for example according to the criteria described above.

(73) It is clear that it is not excluded to provide coolers with more than two stages.

(74) It is also clear that more or fewer partitions 31 can be provided in order to make the number of passes the coolant makes through the tubes 26 greater or smaller.

(75) In addition, the partitions do not necessarily have to be straight.

(76) The present invention is by no means limited to the embodiments described as an example and shown in the drawings, but a compressor device according to the invention and a cooler applicable therewith can be realised in different variants without departing from the scope of the invention.