Modernization of Compressor Equipment Working in Off–Design Modes by Integrating a Turbine–Generator into the Bypass Line

The constant increase of manufacturing capacity leads to the consumption of huge amounts of energy resources, the cost of which continues to grow. Inefficient usage of electric power due to the operation of the equipment in off–design modes leads to an increase in maintenance costs, bringing to light the issue of the equipment modernization. The research shows that it is appropriate to integrate a turbo-generator into the bypass line when the compressor works in off–design modes, e.g. when the capacity of the compressor is superfluous, and remeasured or unstable pressure forces the compressor to unload often. This will make it possible to reduce the costs through energy recovery when the compressed gas is bypassed through the bypass line and when its potential is realized on the turbine wheel using an electric generator. To demonstrate the efficiency and benefits of such recovery through the bypass, the constant average gas flow is assumed as 20% of the compressor’s capacity. Various design versions of the axial–radial turbine wheels for the turbo-generator are studied and the most effective one is selected. The data obtained is verified by calculating the vortex-type pneumatic drive.

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