The present application relates generally to a water injected screw compressor including cooperating rotors. More particularly, the present application relates to rotary screw compressor adapted to deliver oil free air from a water cooled compression chamber.
One embodiment of the present application is a unique water cooled screw compressor. Another embodiment is a rotary screw compression system. Other embodiments include methods, systems, apparatuses, devises, hardware and combinations for rotary screw compressors. Further embodiments, forms, features, aspects, benefits and advantages of the present application will become apparent from the description and figures provided herewith.
The description herein makes reference to the accompanying drawings wherein like reference numeral refer to like parts throughout several views and wherein:
For purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
With reference to
The compressor unit 10 is coupled via a working fluid outlet to an inlet of machinery and/or equipment utilizing the compressed working fluid. In one form the compressed working fluid is disposed in fluid communication with a user's compressed working fluid network. In one aspect the present application is directed to the delivery of pressurized oil free working fluid from an oil free compression chamber environment. More specifically, the compression chamber which houses the rotatable rotors is free of oil and oil related materials whether considered a petrochemical based oil or a synthetic based oil. The term as utilized herein is intended to refer generally to a class of lubricants that are either petroleum or synthetic based and have a variety of viscosities; non limiting examples include grease or oil. The working fluid entering the compression chamber of the rotary screw compressor undergoes a pressure rise based upon the work of the screw compressor rotors and is not exposed to oil and therefore the working fluid exits the rotary screw compressor with no increase in oil content. In a preferred form of the present application the working fluid entering the suction side of the rotary compressor is free of oil.
With reference to
In the single stage rotary screw compressor 17 there is contemplated a variety of pressure ratios: in one form of the present application the pressure ratio when the working fluid is air is about 8:1 and in another form of the present application the pressure ratio is about 10:1. However, the present application is not intended to be limited to the preceding pressure ratios unless specifically stated to the contrary. In one form of the present application the ambient working fluid entering the bore/working fluid chamber within the compressor housing is subjected to a pressure rise commensurate with a pressure ratio of 10:1 and the male and female screw rotors are driven by the power source 13 at a rotational speed of about 10,000 revolutions-per-minute (RPM). The pressure rise from the work performed by the rotors on the working fluid causes a temperature increase of the working fluid. A temperature control system 16 is disposed in fluid communication with the bore/working fluid chamber to control the temperature of the working fluid.
The temperature control system 16 includes a source 18 for water that is delivered through at least one supply conduit 19 to the bore/working fluid chamber within the compressor housing. In one form the water is delivered directly into the bore/working fluid chamber, and in a preferred form the water is delivered to the male and female screw rotors that are working on the working fluid. In one form of the present application the water is clean water so as to be substantially free of contaminants and minerals. In another form of the present application the water is potable water. The present application further contemplates embodiments of the present application that may utilize water that includes additives; a preferred form of additives being non-toxic. In one form the quantity of water delivered into the bore/working fluid chamber is sufficient to remove a portion of the quantity of heat emitted into the working fluid from the heat of compression without flooding the bore/working fluid chamber. The applicants have found that in one form of the present application a comparison of the quantity of water contemplated for the present application and a flooded system is on the order of no more than about five percent (5%) of the amount of water utilized in a water flooded system. One aspect of the present application facilitates the removal of the portion of the heat of compression from the working fluid to have the discharge temperature of the pressurized working fluid to be at a temperature level useable by the end user without requiring additional cooling. In one non limiting example the desired maximum temperature for the discharged working fluid is about 250 degrees Fahrenheit However, the present application contemplates some systems where the end user desires additional cooling.
The present application contemplates that the water delivered to the bore/working fluid chamber can be either steady, non steady state or pulsed. Further, the present application contemplates that a parameter of the working fluid could be sensed or monitored and based upon the outcome of this sensing or monitoring the delivery of cooling water to the bore/working fluid chamber could be adjusted. Therefore, in another form of the present application there is contemplated a temperature control system having a feedback loop based upon a sensed or monitored parameter to adjust the amount of water delivered. In one form of the present application, looking at a sensed or monitored parameter of the temperature of the discharge working fluid is monitored and the quantity of water delivered to the bore/working fluid chamber is adjusted to compensate for the amount of heat that is desired to be removed to meet a target temperature. The present application contemplates that other parameters could be looked at for utilization in the feedback loop such as the discharge pressure of the working fluid and then translated through a table or algorithm.
With reference to
With reference to
In the two stage rotary screw compressor system 30 there is contemplated a variety of pressure ratios for each of the first rotary screw compressor 31 and the second rotary screw compressor 32. In one form of the present application the first rotary screw compressor 31 operates at about nine thousand RPM and the pair of rotors are drivers at this speed and the second rotary screw compressor 32 operates at about fifteen thousand RPM and the pair of rotors are driven at this speed. The pressure rise from the work performed by the first rotary screw compressor 31 causes a temperature increase in the working fluid.
The temperature control system 16 includes a source 18 for water that is delivered through supply conduits 19 and 19a to the respective bore/working fluid chambers within the compressor housings. In one form the water is delivered directly into the bore/working fluid chamber of the first rotary screw compressor 31, and in a preferred form the water is delivered to the male and female screw rotors that are working on the working fluid. In one form of the present application the water is clean water so as to be substantially free of contaminants and minerals. In another form of the present application the water is potable water. The present application further contemplates embodiments of the present application that may utilize water that includes additives. In one form the quantity of water delivered into the bore/working fluid chamber is sufficient to remove a portion of the quantity of heat emitted into the working fluid from the heat of compression without flooding the bore/working fluid chamber. The applicants have found that in one form of the present application a comparison of the quantity of water contemplated for the present application in the first rotary screw compressor and a flooded system is on the order of no more than about five percent (5%) of the amount of water utilized in a water flooded system. One aspect of the present application facilitates the removal of the portion of the heat of compression from the working fluid to have the discharge temperature of the pressurized working fluid to be at a predetermined temperature level acceptable for introduction into the second rotary screw compressor 32.
The present application contemplates that the water delivered to the bore/working fluid chamber can be either steady, non steady state or pulsed. Further, the present application contemplates that a parameter of the working fluid could be sensed or monitored and based upon the outcome of this sensing or monitoring the delivery of cooling water to the bore/working fluid chamber could be adjusted. Therefore, in another form of the present application there is contemplated a temperature control system having a feedback loop based upon a sensed or monitored parameter to adjust the amount of water delivered. In one form of the system looking at a sensed or monitored parameter the temperature of the discharge working fluid is monitored and the quantity of water delivered to the bore/working fluid chamber is adjusted to compensate for the amount of heat that is desired to be removed to meet a target temperature. The present application contemplates that other parameters could be looked at for utilization in the feedback loop such as the discharge pressure of the working fluid and then translated through a table or algorithm.
In one form the water is delivered directly into the bore/working fluid chamber of second rotary screw compressor 32, and in a preferred form the water is delivered onto the male and female screw rotors that are working on the working fluid. In one form of the present application the water is clean water so as to be substantially free of contaminants and minerals. In another form of the present application the water is potable water. The present application further contemplates embodiments of the present application that may utilize water that includes additives. In one form the quantity of water delivered into the bore/working fluid chamber is sufficient to remove a portion of the quantity of heat emitted into the working fluid from the heat of compression without flooding the bore/working fluid chamber. The applicants have found that in one form of the present application a comparison of the quantity of water contemplated for the present application in the first rotary screw compressor and a flooded system is on the order of no more than about five percent (5%) of the amount of water utilized in a water flooded system. One aspect of the present application facilitates the removal of the portion of the heat of compression from the working fluid to have the discharge temperature of the pressurized working fluid to be at a predetermined temperature level useable by the end user. In one non limiting example the desired maximum temperature for the discharged working fluid is about 250 degrees Fahrenheit.
The present application contemplates that the water delivered to the bore/working fluid chamber can be either steady, non steady state or pulsed. Further, the present application contemplates that a parameter of the working fluid could be sensed or monitored and based upon the outcome of this sensing or monitoring the delivery of cooling water to the bore/working fluid chamber could be adjusted. Therefore, in another form of the present application there is contemplated a temperature control system having a feedback loop based upon a sensed or monitored parameter to adjust the amount of water delivered. In one form of the system looking at a sensed or monitored parameter the temperature of the discharge working fluid is monitored and the quantity of water delivered to the bore/working fluid chamber is adjusted to compensate for the amount of heat that is desired to be removed to meet a target temperature. The present application contemplates that other parameters could be looked at for utilization in the feedback loop such as the discharge pressure of the working fluid and then translated through a table or algorithm.
With further reference to
With reference to
The single stage rotary screw compressor 50 includes a housing 53 with a bore/working fluid chamber 54. Disposed within the bore/working fluid chamber 54 is the male screw rotor 51 and the female screw rotor 52. The inner surface 70 of the bore/working fluid chamber 54 includes a abradable coating 71 to facilitate a seal between the outer periphery of the respective rotors and the inner surface 70 of the bore/working fluid chamber 54. The face of the rotors 51a and 52a include an abradable coating for providing a seal to the regions as the working fluid undergoes an increase in pressure. In one form of the present application the abradable coating is a polymer coating. The bore/working fluid chamber 54 is free from oil and oil related materials and the working fluid passing through the bore/working fluid chamber 54 does not have oil or oil related materials imparted thereto. The male and female rotors rotate on bearings 60 that include oil and/or oil related lubricants. One of skill in the art wilt fully understand that the bearings are lubricated with an oil related product that includes materials such as grease. The bearings 60 and the associated oil products in the bearing housings 62 are isolated from the bore/working fluid chamber 54 by seals 61. The seals 61 seal along the shafts of the rotors 51 and 52 and maintain the oil and oil related materials within the bearing housings and prevent the contamination of the working fluid within the bore/working fluid chamber 54. The working fluid passing through and pressurized with the bore/working fluid chamber 54 emerges free from the addition of any oil or oil related material.
As discussed previously, the temperature control system includes a source 18 for water that is delivered through at least one supply conduit 19 to the bore/working fluid chamber 54 within the compressor housing 53. In one form the water is delivered directly into the bore/working fluid chamber 54, and in a preferred form the water is delivered to the male and female screw rotors 51, 52 that are working on the working fluid. In one form of the present application the water is clean water so as to be substantially free of contaminants and minerals. In another form of the present application the water is potable water. The present application further contemplates embodiments of the present application that may utilize water that includes additives. In one form the quantity of water delivered into the bore/working fluid chamber is sufficient to remove a portion of the quantity of heat emitted into the working fluid from the heat of compression without flooding the bore/working fluid chamber 54. The applicants have found that in one form of the present application a comparison of the quantity of water contemplated for the present application and a flooded system is on the order of no more than about five percent (5%) of the amount of water utilized in a water flooded system. One aspect of the present application facilitates the removal of the portion of the heat of compression from the working fluid to have the discharge temperature of the pressurized working fluid to be at a temperature level useable by the end user. In one non limiting example the desired maximum temperature for the discharged working fluid is about 250 degrees Fahrenheit.
The present application contemplates that the water delivered to the bore/working fluid chamber can be either steady, non steady state or pulsed. Further, the present application contemplates that a parameter of the working fluid could be sensed or monitored and based upon the outcome of this sensing or monitoring the delivery of cooling water to the bore/working fluid chamber could be adjusted. Therefore, in another form of the present application there is contemplated a temperature control system having a feedback loop based upon a sensed or monitored parameter to adjust the amount of water delivered. In one form of the system looking at a sensed of monitored parameter the temperature of the discharge working fluid is monitored and the quantity of water delivered to the bore/working fluid chamber is adjusted to compensate for the amount of heat that is desired to be removed to meet a target temperature. The present application contemplates that other parameters could be looked at for utilization in the feedback loop such as the discharge pressure of the working fluid and translated through a table or algorithm.
With reference to
Embodiments of the present invention include rotary screw compressor system, comprising:
a housing including a surface defining at least a portion of an internal working fluid volume free of oil, at least a portion said surface including an abradable coating;
a first pair of oil lubricated bearings;
a second pair of oil lubricated bearings;
a male screw rotor rotatable on said first pair of oil lubricated bearings, said male screw rotor having a first outer surface disposed within said internal working volume;
a female screw rotor rotatable on said second pair of oil lubricated bearings, said female screw rotor having a second outer surface disposed within said internal working volume and intermeshing with said male rotor, at least one of said outer surfaces including a second abradable coating;
a power source coupled with an operable to rotate said rotors;
a temperature controller in fluid communication with said internal working fluid volume and operable to deliver a quantity of water to the working fluid within the internal working fluid volume to remove a portion of the heat of compression to obtain a predetermined discharge temperature for the working fluid without flooding the internal working fluid volume; and
wherein the internal working fluid volume is isolated from said oil lubricated bearings to isolate the working fluid from oil contamination.
In a refinement the rotary screw compressor system includes that the temperature controller delivers a continuous spray of water onto at least one of said rotors.
In another refinement the rotary screw compressor system includes that the temperature controller delivers a continuous spray of water onto both of said rotors.
In yet another refinement the rotary screw compressor system includes that the quantity of water delivered to the working fluid within said internal working fluid volume is no more than about five percent of the quantity of water necessary to define a flooded environment.
In yet further refinement the rotary screw compressor system includes that the quantity of water delivered to the working fluid within said internal working fluid volume is within a range of about two percent to four percent of the quantity of water that would be necessary to define a flooded environment.
In yet further refinement the rotary screw compressor system includes that the compression ratio is about 10:1.
In yet further refinement the rotary screw compressor system includes that the compression ratio is about 8:1.
In yet further refinement the rotary screw compressor system includes that the quantity of water delivered to the working fluid within said internal working fluid volume is no more than five percent of the quantity of water that would be utilized to define a flooded environment,
wherein said temperature controller includes a volume of clean water;
wherein the compression ratio is at least about 8:1; and
wherein said predetermined discharge temperature is about 250° F.
In yet another refinement the rotary screw compressor includes that the volume of clean water is defined by potable water.
In yet another refinement the rotary screw compressor system includes that the compression ratio is about 10:1; and wherein said male and female rotors are driven at about 10,000 RPM.
Embodiments of the present invention include rotary screw compression system, comprising:
a power source:
a rotary screw compressor having a housing with a male and a female rotor rotatably disposed therein, said rotors driven by said power source to increase the pressure ration of an oiless working fluid, at least one of said rotors include a sealing coating; and
a cooling system disposed in fluid communication with said rotors and operable to deliver a dose of water to at least one of said rotors, said dose being about five percent of the dose of water required to define a flooded environment.
In a refinement the rotary screw compression system includes that the dose is a continuous stream of water, and the working fluid is air.
In yet another refinement the rotary screw compression system includes that the dose is a pulsed stream of water, and the working fluid is air.
In yet another refinement the rotary screw compression system includes that the dose keeps the discharge temperature of the working fluid below 250 degrees Fahrenheit.
In yet another refinement the rotary screw compression system further includes a sensor for sensing the temperature of the working fluid at the discharge of said rotary screw compressor; and
said dose is dependent upon the temperature at the discharge of said rotary screw compressor.
In yet another refinement the rotary screw compression system includes that the rotary screw compressor is the sole mechanism for compression.
In yet another refinement the rotary screw compression system is limited to a single stage of compression.
In yet another refinement the rotary screw compression system includes that the dose is a continuous stream of water;
the working fluid is defined by air;
wherein said dose keeps the discharge temperature of the working fluid below a predetermined value of 250 degrees Fahrenheit; and
which further includes a sensor for sensing the temperature of the working fluid at the discharge of rotary screw compressor; and
said dose is dependent upon the temperature at said sensor.
In yet another refinement the rotary screw compression system includes only a single stage of compression.
In yet another refinement the rotary screw compression system includes that the dose is a pulsed stream of water;
the working fluid is defined by air;
wherein said dose keeps the discharge temperature of the working fluid below 250 degrees Fahrenheit;
which further includes a sensor for sensing the temperature of the working fluid at the discharge of said rotary screw compressor; and
said dose is dependent upon the temperature at said sensor.
In yet another refinement the rotary screw compression system further includes a second rotary screw compressor with a second male and a second female rotor disposed therein, said rotors operable to increase the pressure ratio of an oiless working fluid delivered from said rotary screw compressor.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment(s), but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as permitted under the law. Furthermore it should be understood that while the use of the work preferable, preferably, or preferred in the description above indicates that feature so described may be more desirable, it nonetheless may not be necessary and any embodiment lacking the same may be contemplated as within the scope of the invention, that scope being defined by the claims that follow. In reading the claims it is intended that when works such as “a,” “an” “at least one” and “at least a portion” are used, there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. Further, when the language “at least a portion” and/or “a portion” is used the item may include a portion and/or the entire item unless specifically stated to the contrary.
Number | Date | Country | |
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61539459 | Sep 2011 | US |
Number | Date | Country | |
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Parent | PCT/US2012/057356 | Sep 2012 | US |
Child | 14226079 | US |