This application is the US National Stage of International Application No. PCT/EP2016/053826 filed Feb. 24, 2016, and claims the benefit thereof. The International Application claims the benefit of German Application No. DE 102015204466.1 filed Mar. 12, 2015. All of the applications are incorporated by reference herein in their entirety.
The invention relates to an arrangement having a first compressor train and a second compressor train for compressing a process fluid, wherein the first compressor train comprises a first drive and a first compressor, wherein the second compressor train comprises a second drive and a second compressor, wherein the first compressor train is not mechanically coupled in torque-transmitting fashion to rotating parts of the second compressor train, wherein the two compressors of the different compressor trains are directly connected in fluid-conducting fashion to one another by means of a connecting fluid line, in such a way that the first compressor is arranged upstream of the second compressor. The invention also relates to a method for retrofitting a first compressor to an existing installation comprising a second compressor in order, during the course of the retrofitting, to obtain an arrangement according to the invention from an existing installation.
The invention is concerned substantially with increasing the power of compressor installations. Two crucial parameters with regard to the power are the volume flow and the pressure ratio of outlet pressure to inlet pressure of a corresponding compressor installation. In order, in the case of a predefined number of compressor stages, to further increase the power of the compressor installation, there are substantially two available possibilities: increasing the diameter of blade rings or impellers, or increasing the rotational speed. These two design options have been substantially exhausted because the available materials have already reached the limits of their strength characteristic values and accordingly cannot, in terms of forces, withstand any greater circumferential speeds or diameters. Larger diameters furthermore give rise to additional problems with regard to the manufacturing of the rotors, and further challenges with regard to the rotor dynamics.
A field of use of the invention lies in the field of air compressors in the form of geared compressors, the intake by which occurs substantially under atmospheric conditions—possibly with the interposition of a filter, resulting in a pressure below atmospheric pressure at the compressor inlet port—and which compress the intake volume flow to a final pressure of approximately 3 to 200 bar by means of multiple radial compressor stages. A geared compressor is substantially a—relatively large—gearing housing, on the outside of which there are mounted various spiral housings in which the impellers of the radial compressors are driven by gearing pinions. Inter-cooling may be provided in each case between the individual compression stages. The largest diameters of impellers of such radial compressor stages have hitherto been below two meters and, owing to the problems already indicated above, have been increased only with great obstacles in terms of construction, using expensive materials and special manufacturing techniques.
Various multi-stage compression arrangements are already known from the documents US 2012/260693 A1, DE 20 2012 101190 U1, WO 03/040567 A1, GB 1 551 454 A, EP 0 811 770 A1, WO 2009/095097 A1.
Proceeding from the problems discussed above, it is an object of the invention to provide a compressor installation which provides higher power with relatively little outlay. Furthermore, it is an object of the invention to provide a method for retrofitting existing compressor installations such that the respectively retrofitted compressor installation provides higher power, in particular a greater volume flow. Said two objects should not imperatively be associated with the load on components or materials moving closer to corresponding limit values, or with the need to use more expensive materials.
To achieve the object according to the invention, an arrangement of the type mentioned in the introduction having the additional features of the independent claim is proposed. The invention furthermore proposes a method for retrofitting an existing installation as per the method claim. The subclaims with respective back-references encompass advantageous refinements of the invention.
A concept which is essential to the invention consists in increasing the power of a compressor installation such that the process fluid taken in by the second compressor is increased in pressure by a factor of 1.1 to 1.6 upstream of the inflow. This type of precompression or supercharging of the second compressor can—in the case of a substantially unchanged pressure ratio of outlet pressure to inlet pressure of the overall installation—lead to a standard volume flow increase or mass flow increase of between 10% and 40% in relation to a non-supercharged arrangement. The outlay for supercharging according to the invention is relatively low here, because the pressure ratio of the first compressor is small. For such a pressure ratio, it is for example sufficient for a blower to be provided or retrofitted in the inflow to the second compressor, which blower, according to the invention, has a dedicated drive and can accordingly be operated substantially independently of the first compressor. The solution according to the invention is of particular interest as a retrofit solution for existing installations which are incorporated in a process which can be increased in productivity in particular by means of an increase of the volume flow.
An advantageous refinement provides that the second compressor compresses with a pressure ratio between 3 and 60. The ratio of the pressure ratios between the second compressor and the first compressor may advantageously amount to approximately between 2.3 and 56, and the second compressor particularly advantageously has a pressure ratio at least 3.8 times higher than that of the first compressor. For this reason, the first compressor can, owing to the type of construction, be produced at very much lower cost than the second compressor, and may be referred to as a fan (pressure ratio of 1 to 1.3) or blower (pressure ratio of 1.3 to 3.0).
The first drive belonging to the first compressor train may be in the form of either an electric motor, a steam turbine or a gas turbine. For maximum flexibility and lower investment outlay, it is particularly expedient to select an electric motor as first drive. The second drive may likewise be in the form of a turbine or in the form of an electric motor. If process steam is available, operation by means of a steam turbine is particularly advantageous. The first compressor may be in the form of an axial compressor or in the form of a radial compressor, wherein, owing to the low pressure ratio of the first compressor, the term “fan” or “blower” may also be used. Below, the expression “first compressor” will generally be used without regard to a possible pressure ratio of the first compressor, wherein, in the narrower sense, depending on the pressure ratio, said first compressor may be a fan or a blower. In the terminology of this patent application, the expression “first compressor” also encompasses the embodiment of said first compressor as a fan or blower.
A particularly advantageous refinement of the invention provides that the first compressor comprises at least two compressor stages and the first drive is arranged between a first group of compressor stages and a second group of compressor stages.
In the case of an embodiment of the first compressor as an at least two-channel, in particular dual-channel, radial compressor, wherein both radial impellers have in each case an axial intake side and an axial wheel disk side, it may be expedient if the wheel disk side of the first radial impeller faces axially toward the wheel disk side of the second radial impeller and the intake by the two radial impellers occurs axially from opposite directions. Here, the drive may either be arranged axially between the two wheel disk sides or may drive the two impellers axially on one side. The two impellers of the radial compressor may discharge flow into a common diffuser. The dual-channel configuration corresponds to a parallel arrangement of the radial impellers.
An expedient refinement of the invention provides that the arrangement has a filter upstream of the second compressor. Here, it may be expedient if the first compressor is arranged upstream of said filter and if the process fluid is conducted into the second compressor only after passing through the filter. Here, the intake by the first compressor would advantageously occur directly under atmospheric conditions without a filter, and in the case of retrofitting, the downstream installation would possibly need to be adapted to a slightly higher pressure in the filter and upstream of the second compressor in the intake line. Alternatively, the first compressor may also be provided between the filter and the second compressor, such that the process fluid is, downstream of the first compressor, conducted directly into the second compressor without passing through a filter. Here, it is expedient that the filter housing, in particular in the case of retrofitting, does not need to be designed for a slightly increased pressure.
Another advantageous refinement provides that at least the first compressor or the entire first compressor train is arranged in a housing of a filter.
Corresponding filters are often situated with their dedicated housing outside a machine case, such that, in the event of an expansion of a filter of said type, greater freedom in terms of construction exists around for example the first compressor or compressor train than within the machine case, where the second compressor train is arranged. This advantage is also obtained in the case of an arrangement of the first compressor upstream of the filter, as has already been described above.
The arrangement is particularly expediently equipped with a surging protection device. The surging protection device may be provided in particular for protecting the first compressor against a surging process of the second compressor. Owing to the very much greater pressure ratio of the second compressor, corresponding surging processes at said assembly are associated with relatively high potential for destruction. Said surging protection device may advantageously have a closing device which, in the event of surging, closes at least 80% of the flow cross section of the connecting fluid line between the first compressor and the second compressor. Said closing device may expediently have flaps which block the cross-sectional area of the connecting fluid line in the event of a backflow. It is particularly expedient for said flaps to be designed such that, in the event of a backflow movement of the process fluid in the direction of the first compressor, the aerodynamics of the flaps, driven by the backflowing process fluid, moves the flaps into a closing position. For a movement from the closing position back into the opening position, damping may be provided, such that the flaps do not open and close periodically with the surging shocks. It is particularly expedient for the flaps to be designed so as to be mounted so as to be rotatable or pivotable in each case about a spindle. Said spindles extend advantageously perpendicular to a longitudinal axis of the fluid-conducting connection and perpendicular to the main flow direction through the fluid-conducting connection. Said flaps are particularly advantageously arranged adjacent to one another in the manner of lamellae, such that, in an opening position of said flaps, the process fluid flows through the fluid line through a grate formed by the rotary spindles of the flaps. In a closing position, the intermediate spaces between the rotary spindle grates are closed by the louver-like or lamella-like flaps. Alternatively or in addition to the closing device of the surging protection device, it is expedient for a relief device to be provided which, in the event of surging of the first compressor and/or of the second compressor, relieves the connecting fluid line between the first compressor and the second compressor, or at least the section of the fluid line between the closing device and the second compressor, of pressure and/or pressure shocks by means of an opening into a pressure sink, for example the surroundings. Such a relief device and/or closing device is particularly expedient if the first compressor is an axial compressor, because the generally free-standing blades of an axial compressor are sensitive to pressure shocks from surging processes. In the case of a first compressor in the form of a radial compressor, it may be justifiable, in particular for cost reasons, to provide no surging protection device upstream of the second compressor, because a compressor in the form of a radial compressor can be designed to be adequately resilient.
What is particularly expedient is an embodiment of a surging protection device with a relief device which has a slide valve and which is mechanically connected to a closing device. Here, the slide valve may exhibit axial displaceability in a longitudinal direction of the connecting fluid line, which is displaced axially owing to a backflow of the process fluid differential force acting on the closing device, in such a way that a pressure-relieving opening in the connecting fluid line is realized owing to the thus open slide valve.
The arrangement according to the invention is particularly highly suitable for the retrofitting of a first compressor train to a second compressor train of an existing installation, such that an arrangement according to at least one above-described embodiment of the invention is realized. It is particularly expedient for the first compressor to be retrofitted to the existing second compressor, wherein the second compressor is aerodynamically modified such that the pressure ratio of the second compressor is reduced in relation to the state before the retrofitting. In this way, the overall arrangement composed of first compressor and second compressor realized as a result of retrofitting can have a greater volume flow than the second compressor alone, at the same time with an identical pressure ratio in relation to the atmosphere. In the retrofit situation, it is often the case that a substantially unchanged pressure ratio, or the same final pressure, is desired, along with a possibly increased volume flow, because the incorporation into the existing process demands the already previously specified final pressure from the overall compression.
An advantageous refinement of the invention provides that the arrangement according to the invention is a constituent part of a gas turbine, such that the second compressor is, with a compressor housing, a direct constituent part of the gas turbine. Here, it is expedient if the first compressor can be optionally incorporated into the flow path of the fresh-air intake, such that, for example, in a manner dependent on the ambient conditions, the first compressor can perform the function of a precompressor for the gas turbine.
A special refinement of this arrangement with first compressor that can be incorporated into the flow path provides a shut-off element, for example a flap and a bypass in addition to a direct intake of the second compressor past the first compressor. The first compressor is arranged in the bypass, such that the precompressor is utilized only when required (for example in the case of seasonal fluctuations) and the intake of the second compressor otherwise occurs directly through the opened flap. When the flap is open, an introduction guide apparatus of the precompressor can be closed, such that no uncontrolled bypass flow to the opened flap occurs.
An advantageous refinement of the invention provides that the first compressor has an inlet guide apparatus, which adapts the inlet cross section to the required intake capacity. The drive of the first compressor is particularly advantageously not regulated in a manner dependent on the setpoint volume flow, such that the regulation of the volume flow through the first compressor is performed, in the case of an approximately constant rotational speed, exclusively by means of the inlet guide apparatus.
Below, the invention will be described in more detail on the basis of a number of exemplary embodiments with reference to drawings, in which:
An arrangement according to the invention having a first compressor train CT1 and a second compressor train CT2 is depicted in
After emerging from the first compressor CO1 of the first compressor train CT1, the process fluid PF passes into a connecting fluid line CFC situated downstream and, further downstream, to a second compressor train CT2. The second compressor train CT2 has a second compressor CO2 which is in the form of a geared compressor, such that a first compressor stage CO21 of the second compressor CO2 is driven by means of a first gearing GR1 and a second compressor stage CO22, situated downstream, of the second compressor CO2 is driven by means of a second gearing GR2. The first gearing GR1 and the second gearing GR2 are driven by means of a second drive DR2, wherein, in a manner which is not illustrated, the two gearings GR1, GR2 are constituent parts of a common gearing of the geared compressor.
Such geared compressors are basically known. These are gearing housings—which are relatively large—on the outside of which spiral housings of the individual compressor stages are flange-mounted. In general, in the gearing, there is arranged a large gear which is driven by a common drive for the individual compressor stages. Normally, said drive is, outside the gearing housing, connected in torque-transmitting fashion to the gearing housing by means of a clutch. The individual compressor stages are driven by means of pinion shafts, of which at least one shaft end, normally both shaft ends, project out of the gearing housing. The impellers of the individual compressor stages are attached, generally so as to be mounted in floating fashion, on the projecting-out shaft ends. Between the individual compressor stages of the geared compressor, the process fluid may be fed to other processes or may simply undergo cooling. Alternatively, the process fluid may also be transferred from one compressor stage directly to the next compressor stage by means of a connecting fluid line. In
The compression in the first compressor train CT1 takes place with a pressure ratio between 1.1 and 1.6. The second compressor train CT2 compresses the process fluid PF to a final pressure of approximately 3 to 60 bar. The intake of the first compressor train CT1 occurs approximately under atmospheric conditions, wherein the process fluid is, in the present case, air. The use as an air compressor is the design type advantageous for the invention. The intake of the first compressor train CT1 occurs slightly below atmospheric pressure because the filter FIT arranged upstream causes a pressure loss.
Such a type of construction of the integrated form of the first compressor train CT1 is illustrated in
Special modularity of the first compressor train CT1 is shown in
Number | Date | Country | Kind |
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10 2015 204 466 | Mar 2015 | DE | national |
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PCT/EP2016/053826 | 2/24/2016 | WO | 00 |
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WO2016/142171 | 9/15/2016 | WO | A |
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