Cylinder-piston application for surge prevention and energy efficiency in an industrial compression unit

Compressions are prevalent in industrial applications and are notable for their substantial energy consumption. Therefore, the simulation and analysis of the compression process are essential for maintenance and energy conservation efforts. These systems are prone to potentially unstable surge conditions, necessitating the use of traditional anti-surge valves that result in considerable energy losses. Ensuring the near-optimal operation of these systems is critical to minimizing energy consumption. In this article, a conceptual framework for a cylinder-piston mechanism is delineated, intended for design and operation as an active surge control system. Additionally, a modular quasi-one-dimensional model is articulated for the transient simulation of an industrial compression system, which integrates models for both the anti-surge and active control systems. The manuscript presents a novel design, featured by a cylinder-piston system integrated with a robust controller, posited as a potential alternative to traditional anti-surge systems. The effectiveness of this design in expanding the operational envelope of the compression system and surge prevention is rigorously examined. Moreover, a thermodynamic model, grounded in the fundamental laws of mass, momentum, and energy conservation, is applied to each component of the system. Furthermore, the manuscript explores the benefits of the innovative design in achieving a marked decrease in energy wastage. Simulation results from a test scenario reveals that the implementation of the cylinder-piston design, as opposed to the conventional anti-surge system, can diminish energy losses and associated pollutant emissions by approximately 33 percent.