RECONFIGURABLE MULTI-STAGE GAS COMPRESSOR
Disclosed embodiments include a reconfigurable multi-stage gas compressor having a first-stage compression cylinder, a second-stage compression cylinder, and two stepped cylinders. Each of the stepped cylinders include first and second compression cylinders. The gas flow paths through the stepped cylinders are configured in a user-selectable configuration to be in series or in parallel so that the reconfigurable multi-stage gas compressor functions as one of: a three-stage compressor, as a four-stage compressor, and as a hybrid three/four stage compressor. In first and second configurations, the system generates four stages of compression and outputs 4-stage compressed gas through a single exit port, and through dual exit ports, respectively. In a third configuration, the system outputs hot and cooled 3-stage compressed gas through first and second ports and 4-stage compressed gas through a third port. In a fourth configuration, the system outputs hot and cooled 3-stage compressed gas with no 4-stage compressed gas.
1 . A method of operating a reconfigurable multi-stage gas compressor system, the multi-stage gas compressor system comprising a first-stage compression cylinder, a second-stage compression cylinder, and two stepped cylinders, each stepped cylinder having first and second compression cylinders, the method comprising:
generating, by the first-stage compression cylinder, a first-stage compressed gas from an inlet gas;
generating, by the second-stage cylinder, a second-stage compressed gas from the first-stage compressed gas;
feeding at least a first portion the second-stage compressed gas in parallel to at least to first compression cylinders of the two stepped cylinders; and
compressing, the second-stage compressed gas received by the first compression cylinders of the two stepped cylinders to generate a third-stage compressed gas from the second-stage compressed gas; and
configuring gas flow paths through second compression cylinders of the stepped cylinders in a series or parallel configuration with the first compression cylinders of the two stepped cylinders such that the multi-stage gas compressor functions as one of: a three stage compressor; as a four stage compressor; and as a hybrid three/four stage compressor.
2 . The method of claim 1 , further comprising:
configuring gas flow paths to flow through second compression cylinders of the stepped cylinders in a series configuration with the first compression cylinders, comprising:
feeding the third-stage compressed gas output from the first compression cylinders of the two stepped cylinders to the second compression cylinders of the two stepped cylinders; and
generating, by the second compression cylinders of the stepped cylinders, a fourth-stage compressed gas from the third-stage compressed gas.
3 . The method of claim 2 , further comprising:
causing the fourth-stage compressed gas to exit the system through a single discharge outlet.
4 . The method of claim 2 , further comprising:
causing the fourth-stage compressed gas to exit the system through dual discharge outlets.
5 . The method of claim 2 , further comprising:
causing a portion of the third-stage compressed gas to exit the system through a first discharge outlet; and
causing the fourth-stage gas to exit the system through a second discharge outlet.
6 . The method of claim 2 , further comprising:
cooling the first-stage compressed gas, the second-stage compressed gas, and a first portion of the third-stage compressed gas using respective first, second, and third coolers.
7 . The method of claim 6 , further comprising:
processing the cooled first-stage compressed gas, the cooled second-stage compressed gas, and the cooled first portion of the third-stage compressed gas using respective first, second, and third scrubbers.
8 . The method of claim 6 , further comprising:
causing the fourth-stage compressed gas to exit the system through a first discharge outlet;
causing the first portion of cooled third-stage compressed gas to exit the system through a second discharge outlet; and
causing a second portion of uncooled third-stage compressed gas to exit the system through a third discharge outlet.
9 . The method of claim 1 , further comprising:
configuring gas flow paths to flow through second compression cylinders of the stepped cylinders in a parallel configuration with the first compression cylinders;
feeding the first portion of the second-stage compressed gas to the respective first compression cylinders;
feeding a second portion of the second-stage compressed gas to the respective second compression cylinders of the two stepped cylinders; and
generating, by the respective second compression cylinders of the stepped cylinders, a second portion of third-stage compressed gas from the second portion of the second-stage compressed gas.
10 . The method of claim 9 , further comprising:
cooling the first portion of the third-stage compressed gas;
causing the cooled first portion of the third-stage compressed gas to exit the system through a first discharge outlet; and
causing the uncooled second portion of third-stage compressed gas to exit the system through a second discharge outlet.
11 . The method of claim 1 , further comprising:
configuring gas flow paths to flow through the second compression cylinders of the stepped cylinders in a series and parallel configuration with the first compression cylinders;
feeding the first portion of the second-stage compressed gas to the first compression cylinders of the two stepped cylinders;
feeding a second portion of the second-stage compressed gas to one of the second compression cylinders of the two stepped cylinders; and
generating, by the first compression cylinders and the one of the second compression cylinders the third-stage compressed gas from the second-stage compressed gas;
feeding a portion of the third-stage compressed gas to the other of the second compression cylinders of the two stepped cylinders; and
generating, by the other of the second compression cylinders, a fourth-stage compressed gas from the portion of the third-stage compressed gas.
12 . The method of claim 11 , further comprising:
cooling at least a portion of the third-stage compressed gas;
causing the cooled first portion of the third-stage compressed gas to exit the system through a first discharge outlet; and
causing an uncooled second portion of third-stage compressed gas to exit the system through a second discharge outlet.
causing the fourth-stage compressed gas to exit the system through a third discharge outlet.
13 . A method of operating a reconfigurable multi-stage gas compressor system, the multi-stage gas compressor system comprising a first-stage compression cylinder, a second-stage compression cylinder, a first stepped cylinder having a first larger bore stage and a first smaller bore stage, a second stepped cylinder having a second larger bore stage and a second smaller bore stage larger, a first plumbing line fluidly connecting inlets of all bore stages, a second plumbing line fluidly connecting outlets of all the bore stages, and a plurality of valves in the first and second plumbing lines for selecting connecting and isolating one or more of the bore stages, the method comprising:
generating, by the first-stage compression cylinder, a first-stage compressed gas from an inlet gas;
generating, by the second-stage cylinder, a second-stage compressed gas from the first-stage compressed gas;
feeding at least a first portion the second-stage compressed gas in parallel to at least to the first and second larger bore stages of the first and second stepped cylinders; and
selectively setting the plurality valves to control flow paths through the first and second plumbing lines such that the smaller bore stages are in a series, parallel or series and parallel configuration with the larger bore stages of the two stepped cylinders such that the multi-stage gas compressor functions as one of: a four stage compressor generating fourth-stage compressed gas; as a three-stage compressor generating third-stage compressed gas; and as a hybrid three/four stage compressor generating third-stage compressed gas and fourth-stage compressed gas, respectively.
14 . The method of claim 13 , further comprising:
configuring the plurality of valves to cause the flow paths to flow through the smaller stage bores of the stepped cylinders in a series configuration with the larger stage bores compression cylinders, comprising:
feeding third-stage compressed gas output from the larger stage bores of the two stepped cylinders to the smaller stage bores of the two stepped cylinders; and
generating, by the smaller stage bores of the stepped cylinders, a fourth-stage compressed gas from the third-stage compressed gas.
15 . The method of claim 14 , further comprising:
causing a portion of the third-stage compressed gas to exit the system through a first discharge outlet; and
causing the fourth-stage gas to exit the system through a second discharge outlet.
16 . The method of claim 14 , further comprising:
causing the fourth-stage compressed gas to exit the system through dual discharge outlets.
17 . The method of claim 13 , further comprising:
configuring the plurality of valves to cause the flow paths to flow through the smaller stage bores of the stepped cylinders in a parallel configuration with the larger stage bores of the stepped cylinders;
feeding a first portion of the second-stage compressed gas to the larger stage bores of the stepped cylinders;
feeding a second portion of the second-stage compressed gas to the smaller stage bores of the stepped cylinders; and
generating, by the larger stage bores and the smaller stage bores third-stage compressed gas from the first and second portions of the second-stage compressed gas.
18 . The method of claim 9 , further comprising:
cooling a first portion of the third-stage compressed gas;
causing the cooled first portion of the third-stage compressed gas to exit the system through a first discharge outlet; and
causing an uncooled second portion of third-stage compressed gas to exit the system through a second discharge outlet.
19 . The method of claim 13 , further comprising:
configuring the plurality of valves to cause the flow paths to flow through the smaller bore stages of the stepped cylinders in a series and parallel configuration with the larger bore stages;
feeding a first portion of the second-stage compressed gas to the larger bore stages of the stepped cylinders;
feeding a second portion of the second-stage compressed gas to one of the smaller bore stages of the stepped cylinders; and
generating, by the larger bore stages and the one of the smaller bore stages third-stage compressed gas from the second-stage compressed gas;
feeding a portion of the third-stage compressed gas to the other of the smaller bore stages of the stepped cylinders; and
generating, by the other of the smaller bore stages, a fourth-stage compressed gas from the portion of the third-stage compressed gas.
20 . The method of claim 19 , further comprising:
cooling at least a portion of the third-stage compressed gas;
causing the cooled first portion of the third-stage compressed gas to exit the system through a first discharge outlet; and
causing an uncooled portion of third-stage compressed gas to exit the system through a second discharge outlet.
causing the fourth-stage compressed gas to exit the system through a third discharge outlet.