Research on Thermal Performance Prediction Algorithm for Piston Compressors under Non-design Working Conditions

doi:10.3901/JME.2025.14.297

Abstract

Abstract: Hydrogen compressors are the core power equipment of hydrogen refueling stations. To improve pressurization efficiency and ensure safety and reliability, it is necessary to efficiently and accurately predict and monitor the thermal performance of compressors under variable operating conditions. Previous algorithms have the drawback of poor iterative convergence stability in non-design working conditions. The reasons for iteration divergence of thermal performance prediction calculation are analyzed, and a prediction algorithm for piston compressors is proposed. A python-based thermodynamic calculation program is developed. A multi-stage compression numerical calculation model is established and related experiments are conducted, verifying the feasibility of the proposed algorithm. The results indicate that two reasons for iteration divergence of previous algorithms are that there is no unified coordination and restriction for pressure ratios of all stages during the calculation process, and the previous formulas of intake volume calculation are not suitable for the recalculation in the case when a certain stage is in a passive intake condition. A unified pressure ratio adjustment algorithm is proposed to address iterative divergence, and range limitation for pressure ratio adjustment is provided. The original intake calculation formula is improved, which can be applied to performance prediction calculations under both active and passive intake conditions. The proposed algorithm has better stability than previous algorithms in the case of non-design working conditions. It can provide a theoretical basis for predicting and calculating the thermal performance of piston compressors, as well as for their selection and design.

Key words: reciprocating piston compressors, performance prediction, thermal calculation, non-design working conditions

CLC Number:

TG156

KANG Xiang, LI Pengfei, BAI Xueer, LI Yun. Research on Thermal Performance Prediction Algorithm for Piston Compressors under Non-design Working Conditions[J]. Journal of Mechanical Engineering, 2025, 61(14): 297-305.

References

[1] 吴一梅，邵双全，陈建业，等. 车辆配置对气态加氢站预冷负荷的影响[J]. 工程热物理学报，2023，44(9): 2347-2354. WU Yimei，SHAO Shuangquan，CHEN Jianye，et al. Effect of vehicle configurations on the precooling load of a hydrogen station[J]. Journal of Engineering Thermophysics，2023，44(9):2347-2354.
[2] TIAN Z，LÜ H，ZHOU W，et al. Review on equipment configuration and operation process optimization of hydrogen refueling station[J]. International Journal of Hydrogen Energy，2022，47(5):3033-3053.
[3] TIAN H，LI R，YANG L. Operation status monitoring of reciprocating compressors based on the fusion of spatio-temporal multiple information[J]. Measurement，2022，204:112087.
[4] XIAO L，CHEN J，WU Y，et al. Effects of pressure levels in three-cascade storage system on the overall energy consumption in the hydrogen refueling station[J]. International Journal of Hydrogen Energy，2021，46(61):31334-31345.
[5] 张万凌，康祥，李云，等. 70 MPa加氢站大流量氢压机设计方案[J]. 化工机械，2022，49(4):664-669，682. ZHANG Wanling，KANG Xiang，LI Yun，et al. Design scheme for large-flow hydrogen compressor in 70 MPa hydrogen fueling station[J]. Chemical Engineering & Machinery，2022，49(4):664-669，682.
[6] 郁永章. 容积式压缩机技术手册:化工，动力，制冷[M]. 北京:机械工业出版社，2000. YU Yongzhang. Technical manual for positive displacement compressors:Chemical，power，refrigeration[M]. Beijing:China Machine Press，2000.
[7] ZHAO B，JIA X，SUN S，et al. FSI Model of valve motion and pressure pulsation for investigating thermodynamic process and internal flow inside a reciprocating compressor[J]. Applied Thermal Engineering，2018，131:998-1007.
[8] SUN X，ZHANG J，WANG Y，et al. Optimization of capacity control of reciprocating compressor using multi-system coupling model[J]. Applied Thermal Engineering，2021，195:117175.
[9] QI G，ZHU Z，ERQINHU K，et al. Fault-diagnosis for reciprocating compressors using big data and machine learning[J]. Simulation Modelling Practice and Theory，2018，80:104-127.
[10] 周天旭，王存智，郑学鹏. 往复压缩机级间压力的多影响因素耦合分析[J]. 石油化工设备技术，2023，44(6):18-21. ZHOU Tianxu，WANG Cunzhi，ZHENG Xuepeng. Coupling analysis of multi-factor on interstage pressure of reciprocating compressors[J]. Petrochemical Equipment Technology，2023，44(6):18-21.
[11] 李锦龙，冯乐军，宫兰华，等. 基于复算性热、动力计算的往复式压缩机参数分析[J]. 石油化工设备，2012，41(5):81-85. LI Jinlong，FENG Lejun，GONG Lanhua，et al. Parameters analysis and optimization for reciprocating compressors based on checking thermodynamic and dynamic calculations[J]. Petro-Chemical Equipment，2012，41(5):81-85.
[12] 胡家顺. 活塞式压缩机变工况计算的改进[J]. 压缩机技术，1992(4):9-14. HU Jiashun. Improvement of variable operating condition calculation for piston compressors[J]. Compressor Technology，1992(4):9-14.
[13] 周天旭. 无级流量调节系统对往复压缩机级间压力的影响及控制[J]. 石油化工设备技术，2020，41(6):23-25. ZHOU Tianxu. Influence and control of stepless flow regulation system on inter-stage pressure of reciprocating compressor[J]. Petrochemical Equipment Technology，2020，41(6):23-25.
[14] 王海，王苗，王素金，等. 微型高压压缩机热力复算模型改进[J]. 压缩机技术，2015(2):14-17. WANG Hai，WANG Miao，WANG Sujin，et al. Improvements of thermodynamic calculation model of high-pressure micro-compressor[J]. Compressor Technology，2015(2):14-17.
[15] REN S，JIA X，JIANG J，et al. Effect of hydraulic oil compressibility on the volumetric efficiency of a diaphragm compressor for hydrogen refueling stations[J]. International Journal of Hydrogen Energy，2022，47(34):15224-15235.
[16] 方巍，全东方，徐虎乔，等. 活塞式压缩机变工况下压力分配计算[J]. 压缩机技术，1984(4):7-11. FANG Wei，QUAN Dongfang，XU Huqiao，et al. Calculation of pressure distribution under variable operating conditions of piston compressor[J]. Compressor Technology，1984(4):7-11.
[17] 王慧. 二氧化碳压缩机改造的热力及动力特性分析[D]. 济南:山东大学，2019. WANG Hui. Thermal and dynamic characteristic analysis of carbon dioxide compressor reformation[D]. Jinan:Shandong University，2019.
[18] 杨永久. 活塞式压缩机复算性计算[J]. 压缩机技术，1991(5):17-21，26. YANG Yongjiu. Recalculation of piston compressor[J]. Compressor Technology，1991(5):17-21，26.
[19] 李琴，母德全，张克海，等. 往复压缩机管路气流脉动分析与消减优化[J]. 化工进展，2023，42(11):5612-5621. LI Qin，MU Dequan，ZHANG Kehai，et al. Investigation and optimization of airflow pulsation reduction in the pipeline of a reciprocating compressor[J]. Chemical Industry and Engineering Progress，2023，42(11):5612-5621.
[20] SUN S Y，REN T R. New method of thermodynamic computation for a reciprocating compressor:Computer simulation of working process[J]. International Journal of Mechanical Sciences，1995，37(4):343-353.
[21] NIAZMAND A，FARZANEH-GORD M，DEYMI-DASHTEBAYAZ M. Exergy analysis and entropy generation of a reciprocating compressor applied in CNG stations carried out on the basis models of ideal and real gas[J]. Applied Thermal Engineering，2017，124:1279-1291.
[22] CAMPORESE R，BIGOLARO G，REBELLATO L. Calculation of thermodynamic properties of refrigerants by the Redlich-Kwong-Soave equation of state[J]. International Journal of Refrigeration，1985，8(3):147-151.
[23] FARZANEH-GORD M，NIAZMAND A，DEYMI-DASHTEBAYAZ M，et al. Thermodynamic analysis of natural gas reciprocating compressors based on real and ideal gas models[J]. International Journal of Refrigeration，2015，56:186-197.
[24] ROSKOSCH D，VENZIK V，ATAKAN B. Thermodynamic model for reciprocating compressors with the focus on fluid dependent efficiencies[J]. International Journal of Refrigeration，2017，84:104-116.