HIGH-THROUGHPUT DIAPHRAGM COMPRESSOR
Devices and methods for operating a diaphragm compressor system provide high output pressure and high throughput. In some embodiments, modular diaphragm compressors are stacked with a clamping mechanism pressing the compressor modules together. In embodiments, multiple stacks are provided as stages of a pressurization process. In embodiments, a main stage valve controls one or more pressure circuits for one or more hydraulic actuators of compressor modules. In embodiments, orifices configured for damping are incorporated to control actuator piston movement within a compressor module.
1 . A diaphragm compressor system with main stage valve controlling a hydraulic drive thereof, the diaphragm compressor comprising:
a main stage valve comprising:
a valve body comprising a first end and a second end,
a pilot port proximate the first end,
a supply port,
a first vent port,
a cylinder port, and
a pin subassembly comprising a spool, a pilot pin proximate the second end, and a return pin proximate the first end,
wherein the pin subassembly is configured to move to a supply position with the supply port in fluid communication with the cylinder port and an end orifice configured to dampen motion of the pin subassembly into the supply position, and
wherein the pin subassembly is configured to move to a vent position with the cylinder port in fluid communication with the first vent port and a vent damping orifice configured to dampen motion of the pin subassembly into the vent position; and
a diaphragm compressor system comprising:
a first compressor head comprising:
a head cavity, and
a diaphragm mounted in the head cavity and dividing the head cavity into a work oil region and a process gas region, the diaphragm configured to actuate during a discharge cycle to pressurize process gas in the process gas region,
a hydraulic drive configured to pressurize work oil and provide the pressurized work oil to the compressor head, the hydraulic drive comprising:
a drive housing comprising:
a plurality of ports, the plurality of ports comprising a first port and a second port, wherein the hydraulic drive is configured to provide a variable-pressure supply of work oil to the drive cavity through one or more of the plurality of ports, and
a drive cavity divided into a first actuation volume in communication with the first port and a second actuation volume in communication with the second port;
a hydraulic power unit, and
a plurality of pressure circuits comprising: a low-pressure circuit of work oil at a low pressure, and a high-pressure circuit of work oil at a high pressure, wherein, during the discharge cycle of the first compressor head:
the hydraulic drive is configured to provide the variable-pressure supply of work oil through the second port to the second actuation volume 146 , intensifying the work oil in the first variable volume region to an intensified pressure, and actuating the diaphragm of the first compressor head to the second position,
wherein the main stage valve is mounted to the drive housing with the cylinder port in fluid communication with the drive cavity and the supply port operatively coupled to the hydraulic power unit, and
wherein the main stage valve is configured to selectively move to the supply position to connect the high-pressure circuit to the drive cavity during the discharge cycle of the first compressor head.
2 . The diaphragm compressor system with main stage valve of claim 1 , wherein, during a suction cycle of the first compressor head:
the pin subassembly is configured to move to the vent position to connect the drive cavity of the drive housing to the first vent port of the main stage valve, and
the hydraulic drive vents work oil from the second actuation volume through the main stage valve.
3 . The diaphragm compressor system with main stage valve of claim 1 , the low-pressure circuit of the hydraulic drive further comprising a recovered oil accumulator operatively coupled to the first vent port of the main stage valve,
the main stage valve configured to supply oil from the drive cavity to the recovered oil accumulator when in the vent position.
4 . The diaphragm compressor system with main stage valve of claim 3 , wherein the low-pressure circuit comprises the recovered oil accumulator.
5 . The diaphragm compressor system with main stage valve of claim 4 , further comprising a passive valve operatively connected to the recovered oil accumulator and the drive cavity,
wherein, during the suction cycle of the first compressor head, the passive valve is configured to supply oil from the recovered oil accumulator to the drive cavity.
6 . The diaphragm compressor system with main stage valve of claim 1 , further comprising:
a multi-stage pilot valve mounted in the second end of the valve body, the pilot valve configured to selectively actuate the pin subassembly of the main stage valve,
wherein the hydraulic drive further comprises a pilot pressure circuit and a pilot pressure accumulator operatively coupled to the pilot valve.
7 . The diaphragm compressor system with main stage valve of claim 6 ,
wherein the pilot pressure circuit is operatively coupled to the pilot port at the first end of the valve body, and
wherein the pin subassembly has a larger area proximate the pilot valve than proximate the pilot port and the pin subassembly is configured to move to the supply position when pilot pressure is supplied to the pilot pin through the pilot valve and the pilot port.
8 . The diaphragm compressor system with main stage valve of claim 6 , further comprising a return spring configured to bias the pin subassembly toward the vent position when pressure is not supplied to the pilot valve.
9 . The diaphragm compressor system with main stage valve of claim 1 , wherein the main stage supply valve is a first main stage valve operatively coupled to the first actuation volume of the drive cavity, the diaphragm compressor system with main stage valve further comprising:
a second main stage valve of claim 1 ,
wherein the second main stage valve is mounted to the drive housing with each of the vent port and the cylinder port in fluid communication with the second actuation volume of the drive cavity and the supply port operatively coupled to the hydraulic power unit,
wherein the second main stage valve is configured to selectively move to the supply position to connect the high-pressure circuit to the second actuation volume.
10 . The diaphragm compressor system with main stage valve of claim 1 , further comprising:
at least one of an actuator and a valve mounted in the second end of the valve body configured to selectively actuate the pin subassembly of the main stage valve to the supply position.
11 . The diaphragm compressor system with main stage valve of claim 1 , wherein one or more of the pilot port and the vent damping orifice comprises a plurality of rows of damping orifices comprising a row of relatively larger damping orifices proximate the spool and a row of smaller damping orifices proximate one of the respective first and second end.
12 . The diaphragm compressor system with main stage valve of claim 1 , wherein the pilot port comprises a removable ring of orifices.
13 . A diaphragm compressor system, comprising:
a plurality of pressure circuits comprising a medium-pressure circuit and a high-pressure circuit; and
four or more of the main stage valve of claim 1 , comprising:
a first main stage valve configured to selectively supply the high-pressure circuit to the first actuation volume and vent work oil from the first actuation volume,
a second main stage valve configured to selectively supply the high-pressure circuit to the second actuation volume and vent work oil from the second actuation volume,
a third main stage valve configured to selectively supply the medium-pressure circuit to the first actuation volume and vent work oil from the first actuation volume, and
a fourth main stage valve configured to selectively supply the medium-pressure circuit to the second actuation volume and vent work oil from the second actuation volume.
14 . The diaphragm compressor system of claim 13 , wherein the first and second main stage valves are each configured to vent from the respective first or second actuation volume through the respective first vent port to a recovered oil accumulator.
15 . The diaphragm compressor system of claim 14 , further comprising a passive valve configured to supply oil from the recovered oil accumulator to the drive cavity during the suction cycle of the first compressor head.