Pistonless Apparatus and System for Gas Compression and the Method for Compression of a Gas

In at least one aspect, the present invention is related to a gas compression system.

It is well known that gases and gas mixtures can be compressed to increase pressure for storage. Many compression systems are fluid-controlled, typically using synthetic oils pumped into one side of a cylinder to move a piston and compress the gas. The high temperatures and pressures required necessitate the use of synthetic oil. To prevent oil and gas from mixing, these systems often require isolated piston configurations with seals and gaskets that universally fail over time. Gas or gas mixtures can be compressed to pressures ranging from 10 to 1000 bars and stored in vessels, tanks, and other containers, involving the application of one or more compression units. Compression systems commonly utilize single-stage or multi-stage cylinders, each with piston compression mechanisms.

These compression systems are controlled by liquid fluids (typically synthetic oils), pumped into one side of the cylinder to facilitate piston movement through compression and suction cycles. Maintaining the operational characteristics during these cycles requires the use of synthetic oil to withstand the high temperatures and pressures involved. The integrity of the gas must be preserved, especially in applications like refilling oxygen, hydrogen, methane, helium, and similar gases into vessels or cylinders. Hence, isolation systems containing seals and gaskets for pistons are necessary to prevent oil and gas mixing.

To reduce operational costs, it is common to use oil due to wear on components, even though it can mix with the gas. This issue is particularly problematic in applications involving oxygen and hydrogen, where the presence of lubricating oils is hazardous due to fire and explosion risks. Another significant problem is the high temperature generated during the compression phase. This high temperature leads to thermodynamic variations in gas expansion, fluctuating compression conditions inside the vessel, decreased efficiency, and often provides the gas an a temperature higher than desired. To deliver gas at the correct pressure and temperature, it may be necessary to compress it to a higher pressure and wait for the temperature to balance within the cylinder before moving to the next high temperature, higher pressure stage. In such situations, handling high-temperature, high-pressure vessels and compression stages manually can be problematic and sometimes is not feasible.

Accordingly, there is a need for an improved low-cost gas compression system that avoids thermodynamic variation of expansion and operates at lower temperatures without contamination.

In at least one aspect, a gas compression system includes a first hollow cylinder and a gas source in fluid communication with the first hollow cylinder. The gas source provides a gas that enters the first hollow cylinder. A gas collector tank is in fluid connection with the first hollow cylinder by an outlet line. A liquid holding tank includes liquid in fluid communication with the first hollow cylinder. A pump is in fluid connection with the liquid holding tank and the first hollow cylinder. The system further includes an actuation system configured to control the input of liquid and gas into the first hollow cylinder and the output of gas and liquid from the first hollow cylinder. A controller is configured to control the actuation system. The controller enables the pump to move liquid from the liquid holding tank into the first hollow cylinder at a higher pressure than the gas, thereby causing a liquid surface to move within the first hollow cylinder, compressing the gas. The controller also enables the release of the compressed gas into the gas collector tank when its pressure exceeds a predetermined pressure.

In another aspect, a gas compression system includes a first hollow cylinder with a bottom and top, a gas source allowing relatively uncompressed gas to enter the cylinder through its top, and a gas collector tank connected via an outlet line. The system includes a liquid holding tank with liquid linked to the first cylinder bottom and a pump connecting the liquid holding tank to the cylinder bottom. An actuation system controls the liquid, in this case distilled liquid and gas input/output, while a controller manages the pump to move distilled liquid from the liquid holding tank into the first hollow cylinder through the first cylinder bottom at a higher pressure than the relatively uncompressed gas. This causes vertical liquid movement within the cylinder, compressing the gas, and the controller releases the compressed gas into the collector tank once it surpasses a first predetermined high gas pressure.

In another aspect, the first predetermined high gas pressure is greater than 250 psi.

In another aspect, the gas compression system includes a pressure sensor operatively associated with the outlet line to measure the pressure of the compressed gas.

In another aspect, the gas compression system includes a temperature sensor operatively associated with the outlet line to measure the temperature of the compressed gas.

In another aspect, the gas compression system is operated by a method that includes filling the first hollow cylinder with the relatively uncompressed gas, filling the first hollow cylinder with liquid to compress the relatively uncompressed gas, and then collecting the compressed gas.

In another aspect, the gas compression system includes an actuation system that has a first gas inlet actuated valve and a first gas outlet actuated valve in electrical communication with the controller. The first gas inlet actuated valve is positioned between the first hollow cylinder and the gas source to control the entry of the relatively uncompressed gas into the first hollow cylinder, and the first gas outlet actuated valve is positioned between the first hollow cylinder and the gas collector tank to control the exit of the compressed gas from the first hollow cylinder.

In another aspect, the gas compression system includes an actuation system that has a first liquid inlet actuated valve and a first liquid outlet actuated valve in electrical communication with the controller. The first liquid inlet actuated valve is positioned between the first hollow cylinder and the liquid holding tank to control the entry of liquid into the first hollow cylinder, and the first liquid outlet actuated valve is positioned between the first hollow cylinder and the liquid holding tank to control the exit of liquid from the first hollow cylinder.

In another aspect, the gas compression system is operated by a method and system that includes closing both the first liquid inlet actuated valve and the first liquid outlet actuated valve, opening a gas inlet actuated valve and filling the first hollow cylinder to a predetermined low pressure, closing the gas inlet actuated valve when the pressure is equal to or greater than the predetermined low pressure, opening the first liquid inlet actuated valve to introduce liquid into the first hollow cylinder, closing the first liquid inlet actuated valve when the first predetermined high gas pressure is achieved, opening the first gas outlet actuated valve to allow gas to flow to a gas collector tank and gas-liquid separator vessel, closing the first gas outlet actuated valve when the pressure in the first hollow cylinder falls below a predetermined cylinder pressure, opening the first liquid outlet actuated valve followed by opening the gas inlet actuated valve, closing the gas inlet actuated valve when the pressure is equal to or greater than the predetermined low pressure, and cycling back through a liquid storage tank for holding and then introducing liquid into the first hollow cylinder.

In another aspect, the gas compression system includes a radiator in fluid connection with the first cylinder bottom and the liquid holding tank, where the radiator cools liquid before it enters the liquid holding tank.

In another aspect, the gas compression system includes a second hollow cylinder in fluid connection with the gas source, the liquid holding tank, and the pump. The second hollow cylinder has a second cylinder bottom and a second cylinder top. The controller is further configured to enable the pump to move liquid from the liquid holding tank into the second hollow cylinder at a higher pressure than the relatively uncompressed gas, thereby causing a liquid surface to move in a vertical direction within the second hollow cylinder, compressing the relatively uncompressed gas into compressed gas. The controller also enables the release of the compressed gas into the gas collector tank when its pressure is greater than the first predetermined high gas pressure in the second hollow cylinder.

In another aspect, the gas compression system is configured to compress the relatively uncompressed gas in the first hollow cylinder and the second hollow cylinder for a plurality of cycles.

In another aspect, the gas compression system is configured to sequentially compress the relatively uncompressed gas in the first hollow cylinder and the second hollow cylinder for a plurality of cycles.

In another aspect, the gas compression system is configured to compress the relatively uncompressed gas in the first hollow cylinder and the second hollow cylinder for a plurality of cycles in parallel.

In another aspect, a dual-cylinder gas compression system includes a first hollow cylinder with a first cylinder bottom and a first cylinder top. The system also includes a second hollow cylinder with a second cylinder bottom and a second cylinder top. A gas source supplies relatively uncompressed gas, which enters the first hollow cylinder through the first cylinder top and/or the second hollow cylinder through the second cylinder top. The gas collector tank is connected to the first cylinder top and the second cylinder top by an outlet line. A liquid holding tank contains liquid and is connected to the first cylinder bottom and the second cylinder bottom. A pump connects to the liquid holding tank, the first cylinder bottom, and the second cylinder bottom. The actuation system controls the input of liquid and relatively uncompressed gas into the first hollow cylinder and the second hollow cylinder. It also controls the output of compressed gas and liquid from both cylinders. The controller manages the actuation system. It enables the pump to move liquid from the liquid holding tank into the first hollow cylinder and/or the second hollow cylinder at a higher pressure than the relatively uncompressed gas. This causes a liquid surface to move vertically within the cylinders, compressing the relatively uncompressed gas into compressed gas. The controller also releases the compressed gas into the gas collector tank when its pressure exceeds a first predetermined high gas pressure in either cylinder.

In another aspect, the dual-cylinder gas compression system includes a first predetermined high gas pressure that is greater than 1000 psi.

In another aspect, the dual-cylinder gas compression system includes a pressure sensor operatively associated with the outlet line to measure the pressure of the compressed gas.

In another aspect, the dual-cylinder gas compression system includes a temperature sensor operatively associated with the outlet line to measure the temperature of the compressed gas.

In another aspect, the dual-cylinder gas compression system operates by a method that includes filling the first hollow cylinder with the relatively uncompressed gas, filling the first hollow cylinder with liquid to compress the relatively uncompressed gas, and then collecting the compressed gas.

In another aspect, the dual-cylinder gas compression system includes an actuation system with a first gas inlet actuated valve, a first gas outlet actuated valve, a second gas inlet actuated valve, and a second gas outlet actuated valve, all in electrical communication with the controller. The first gas inlet actuated valve is positioned between the first hollow cylinder and the gas source to control the entry of the relatively uncompressed gas into the first hollow cylinder. The first gas outlet actuated valve is positioned between the first hollow cylinder and the gas collector tank to control the exit of the compressed gas from the first hollow cylinder. The second gas inlet actuated valve is positioned between the second hollow cylinder and the gas source to control the entry of the relatively uncompressed gas into the second hollow cylinder. The second gas outlet actuated valve is positioned between the second hollow cylinder and the gas collector tank to control the exit of the compressed gas from the second hollow cylinder.

In another aspect, the dual-cylinder gas compression system includes an actuation system that has a first liquid inlet actuated valve, a first liquid outlet actuated valve, a second liquid inlet actuated valve, and a second liquid outlet actuated valve, all in electrical communication with the controller. The first liquid inlet actuated valve is positioned between the first hollow cylinder and the liquid holding tank to control the entry of liquid into the first hollow cylinder. The first liquid outlet actuated valve is positioned between the first hollow cylinder and the liquid holding tank to control the exit of liquid from the first hollow cylinder. The second liquid inlet actuated valve is positioned between the second hollow cylinder and the liquid holding tank to control the entry of liquid into the second hollow cylinder. The second liquid outlet actuated valve is positioned between the second hollow cylinder and the liquid holding tank to control the exit of liquid from the second hollow cylinder.

In another aspect, the dual-cylinder gas compression system is operated by a method that includes several steps. First, closing the first liquid inlet actuated valve and the first liquid outlet actuated valve and/or the second liquid inlet actuated valve and the second liquid outlet actuated valve. Next, opening the first gas inlet actuated valve and filling the first hollow cylinder to a predetermined low pressure and/or opening the second gas inlet actuated valve and filling the second hollow cylinder to the predetermined low pressure. Then, closing the first gas inlet actuated valve when the pressure is equal to or greater than the predetermined low pressure and/or closing the second gas inlet actuated valve when the pressure is equal to or greater than the predetermined low pressure. Following this, opening the first liquid inlet actuated valve to introduce liquid into the first hollow cylinder and/or opening the second liquid inlet actuated valve to introduce liquid into the second hollow cylinder. Then, closing the first liquid inlet actuated valve when the first predetermined high gas pressure is achieved and/or closing the second liquid inlet actuated valve when the first predetermined high gas pressure is achieved. Afterward, opening the first gas outlet actuated valve to allow gas to flow to the gas collector tank and/or opening the second gas outlet actuated valve to allow gas to flow to the gas collector tank. Next, closing the first gas outlet actuated valve when the pressure in the first hollow cylinder falls below a predetermined cylinder pressure and/or closing the second gas outlet actuated valve when the pressure in the second hollow cylinder falls below a predetermined cylinder pressure. Then, opening the first liquid outlet actuated valve, followed by opening the first gas inlet actuated valve and/or opening the second liquid outlet actuated valve, followed by opening the second gas inlet actuated valve. Finally, closing the gas inlet actuated valve when the pressure in the first hollow cylinder is equal to or greater than the predetermined low pressure and/or closing the second gas inlet actuated valve when the pressure in the second hollow cylinder is equal to or greater than the predetermined low pressure, and cycling back to introducing liquid into the hollow cylinders.

In another aspect, the dual-cylinder gas compression system includes a radiator in fluid connection with the first cylinder bottom and the liquid holding tank, where the radiator cools liquid before it enters the liquid holding tank.

In another aspect, the dual-cylinder gas compression system is configured to compress the relatively uncompressed gas in the first hollow cylinder and the second hollow cylinder for a plurality of cycles.

In another aspect, the dual-cylinder gas compression system is configured to sequentially compress the relatively uncompressed gas in the first hollow cylinder and the second hollow cylinder for a plurality of cycles.

In another aspect, the dual-cylinder gas compression system is configured to compress the relatively uncompressed gas in the first hollow cylinder and the second hollow cylinder for a plurality of cycles in parallel.

In another aspect, a reaction assembly includes a reactor system that oxidizes a hydrocarbon-containing gas, and the dual-cylinder gas compression system is in fluid communication with the reactor system.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

Reference will now be made in detail to presently preferred compositions, embodiments and methods of the present invention, which constitute the best modes of practicing the invention presently known to the inventors. The Figures are not necessarily to scale. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for any aspect of the invention and/or as a representative basis for teaching one skilled in the art to variously employ the present invention.

Except in the examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material or conditions of reaction and/or use are to be understood as modified by the word “about” in describing the broadest scope of the invention. Practice within the numerical limits stated is generally preferred. Also, unless expressly stated to the contrary: percent, “parts of,” and ratio values are by weight; the term “polymer” includes “oligomer,” “copolymer,” “terpolymer,” and the like; molecular weights provided for any polymers refers to weight average molecular weight unless otherwise indicated; the description of a group or class of materials as suitable or preferred for a given purpose in connection with the invention implies that mixtures of any two or more of the members of the group or class are equally suitable or preferred; description of constituents in chemical terms refers to the constituents at the time of addition to any combination specified in the description, and does not necessarily preclude chemical interactions among the constituents of a mixture once mixed; the first definition of an acronym or other abbreviation applies to all subsequent uses herein of the same abbreviation and applies mutatis mutandis to normal grammatical variations of the initially defined abbreviation; and, unless expressly stated to the contrary, measurement of a property is determined by the same technique as previously or later referenced for the same property.

It is also to be understood that this invention is not limited to the specific embodiments and methods described below, as specific components and/or conditions may, of course, vary. Furthermore, the terminology used herein is used only for the purpose of describing particular embodiments of the present invention and is not intended to be limiting in any way.

It must also be noted that, as used in the specification and the appended claims, the singular form “a,” “an,” and “the” comprise plural referents unless the context clearly indicates otherwise. For example, reference to a component in the singular is intended to comprise a plurality of components.

The term “comprising” is synonymous with “including,” “having,” “containing,” or “characterized by.” These terms are inclusive and open-ended and do not exclude additional, unrecited elements or method steps.

The phrase “consisting of” excludes any element, step, or ingredient not specified in the claim. When this phrase appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.

The phrase “consisting essentially of” limits the scope of a claim to the specified materials or steps, plus those that do not materially affect the basic and novel characteristic(s) of the claimed subject matter.

With respect to the terms “comprising,” “consisting of,” and “consisting essentially of,” where one of these three terms is used herein, the presently disclosed and claimed subject matter can include the use of either of the other two terms.

The term “substantially,” “generally,” or “about” may be used herein to describe disclosed or claimed embodiments. The term “substantially” may modify a value or relative characteristic disclosed or claimed in the present disclosure. In such instances, “substantially” may signify that the value or relative characteristic it modifies is within ±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5% or 10% of the value or relative characteristic.

The term “gas” as used herein mean a single gaseous component or a mixture of gaseous components.

It should also be appreciated that integer ranges explicitly include all intervening integers. For example, the integer range 1-10 explicitly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, the range 1 to 100 includes 1, 2, 3, 4 . . . 97, 98, 99, 100. Similarly, when any range is called for, intervening numbers that are increments of the difference between the upper limit and the lower limit divided by 10 can be taken as alternative upper or lower limits. For example, if the range is 1.1. to 2.1 the following numbers 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0 can be selected as lower or upper limits. In the specific examples set forth herein, concentrations, temperature, and reaction conditions (e.g. pressure, pH, etc.) can be practiced with plus or minus 50 percent of the values indicated rounded to three significant figures. In a refinement, concentrations, temperature, and reaction conditions (e.g., pressure, pH, etc.) can be practiced with plus or minus 30 percent of the values indicated rounded to three significant figures of the value provided in the examples. In another refinement, concentrations, temperature, and reaction conditions (e.g., pH, etc.) can be practiced with plus or minus 10 percent of the values indicated rounded to three significant figures of the value provided in the examples.

In the examples set forth herein, concentrations, temperature, and reaction conditions (e.g., pressure, pH, flow rates, etc.) can be practiced with plus or minus 50 percent of the values indicated rounded to or truncated to two significant figures of the value provided in the examples. In a refinement, concentrations, temperature, and reaction conditions (e.g., pressure, pH, flow rates, etc.) can be practiced with plus or minus 30 percent of the values indicated rounded to or truncated to two significant figures of the value provided in the examples. In another refinement, concentrations, temperature, and reaction conditions (e.g., pressure, pH, flow rates, etc.) can be practiced with plus or minus 10 percent of the values indicated rounded to or truncated to two significant figures of the value provided in the examples.

Throughout this application, where publications are referenced, the disclosures of these publications in their entirety are hereby incorporated by reference into this application to more fully describe the state of the art to which this invention pertains.

Referring to, a schematic of a gas compression system is provided. Gas compression systemincludes the first hollow cylinder, which includes a first cylinder bottomand a first cylinder top. The gas sourceprovides a relatively uncompressed gas in fluid communication through inlet linewith the first cylinder topsuch that relatively uncompressed gas enters the first hollow cylinderthrough the first cylinder top. Gas collector tankis in fluid connection with the first cylinder topby an outlet line. In this context, “relatively uncompressed gas” means gas that the gas is at a predetermined low pressure that is less than the compressed gas produced by gas compression system(typically, the predetermined low pressure is at most 500, 200 or 100 psi). Liquid holding tankincludes liquid (e.g., water) in fluid communication with the first cylinder bottom. Pumpis in fluid connection with the liquid holding tankand the first cylinder bottom. Actuation systemis configured to control the input of liquid and relatively uncompressed gas into the first hollow cylinderand the output of compressed gas and liquid from the first hollow cylinder. Controlleris configured to control the actuation system. Controlleris configured to enable the pumpto move liquid from the liquid holding tank into the first hollow cylinderthrough the first cylinder bottomat a higher pressure than the relatively uncompressed gas, thereby causing a liquid surfaceto move in a vertical direction (or along a center axis of the first hollow cylinder) within the first hollow cylinder, compressing the relatively uncompressed gas into compressed gas. The sequences of gas flow and liquid flow are controlled by a set of actuation valves in electrical communication with controlleras set forth below in more detail. The pressures in first hollow cylinder is read with a pressure sensor. Connections of various components to controllerare shown as dashed lines with angled terminators. Controllerenables the release of the compressed gas into gas collector tankwhen its pressure is greater than the first predetermined high gas pressure. In a refinement, the first predetermined gas high pressure is greater than 1000 psi. In a further refinement, the first predetermined gas high pressure is greater than or e 2000 psi.

In another aspect, the relatively uncompressed gas (and therefore the compressed gas) is oxygen-containing gas such as air.

In another aspect, gas compression systemincludes a pressure sensoroperatively associated with the outlet lineto measure the pressure of a compressed gas. In a refinement, gas compression systemincludes a temperature sensoroperatively associated with the outlet line to measure the temperature of compressed gas. In a refinement, inlet linecan include flow meter, temperature sensor, and pressure sensor.

In another aspect, actuation systemincludes a first gas inlet actuated valveand a first gas outlet actuated valvein electrical communication with the controller. First gas inlet actuated valveis disposed between the first hollow cylinderand the gas sourceto control the entry of the relatively uncompressed gas into the first hollow cylinder. Similarly, the first gas outlet actuated valveis disposed between the first hollow cylinderand the gas collector tankto control the exiting of the compressed gas from the first hollow cylinder.