Design of a Carbon Dioxide Compression Train: For high pressures and low mass flows, using rolling piston compressors

To answer the need for renewable fuels, Zero Emission Fuels is designing a microplant to create methanol from carbon dioxide and water from the ambient air using only renewable energy from solar panels. For this microplant, gaseous carbon dioxide must be compressed from 1 to 50 [bar] with the low mass flow of 336.7 [g/h]. This thesis examines the compression system which uses rolling piston compressors. This thesis also examines a solution to compress the carbon dioxide optimally. Because of the low mass flows, the compressors are very small and have relatively high friction and leakage losses. Meanwhile, due to the high pressure ratio of the system, the temperature increase due to compression also poses a problem for the lubrication of the system. Therefore, this thesis looks for solutions for these problems while trying to gain a better understanding of what exactly is happening inside the compressors. For the temperature regulation, different options for active cooling were assessed with a dimensionless analysis. Eventually, the concept of cooling through the compressor housing was chosen. Afterwards, a computational model was made to calculate the inner workings of the compressors and assess whether the concept of active cooling would still work. Then the computational model was verified by doing experimentation. After that, the results from the model and the experimentation were compared. The model was able to predict the mass flow and the outside heat transfer coefficient accurately. However, the model was still off from the experimental values by quite a margin. After assessing all the data, the system seemed to perform better as a 2-stage system then as a 3-stage system. However, due to the inaccuracies of the model and experimentation, a definite recommendation on the number of stages of the system cannot be formed.
Mechanical Engineering | Energy and Process Technology