Foran Tiangao

APPLICATION

Diaphragm compressors are used in variety of fields, for instance, hydrogen energy application, aerospace, nuclear power, food & beverage, pharmaceutical,
petrochemical industry, electronic industry, material industry, national defense and military industry, scientific test, noble gas extraction, etc.

TOXIC GAS

PF₅, F₂, C₂F₅I, HCl, AHF, NH₃, H₂S
FLAMMABLE GAS

H₂, D₂, CH₄, C₂H₆, C₃H₈, O₂, CO, C₂H₄, VDF
RARE GAS

He, Ne, Ar, Kr, Xe
OTHER GASES

CO₂, N₂, C₃HF₇, C₄F₇N

WORKING PRINCIPLE

Oil side
Perforated Plate
Piston
O-ring
Oil Side Diaphragm
Middle Diaphragm
Gas Side Diaphragm
Gas Side
Coolant Channel
Suction
Discharge
Diaphragm Rupture Detection Channel

The diaphragm set consists of three metal palates, separating process gas and hydraulic oil completely.The motor transmits the power to the crankshaft system by the means of direct or belt transmission to reciprocate the piston.The piston pushes the hydraulic oil and the diaphragm to sweep the cavity contours to maximize displacement and pressurize the gas subsequently. The diaphragms move back and forth under the control of suction and discharge to finish every compression.

PRODUCT ADVANTAGES

Non-contaminating, Leakage-free & Purity Quarantined

Tiangao diaphragm compressor has excellent sealing performance. Static seal could be achieved between gas side and oil side. The diaphragm set completely separates process gas from hydraulic oil. There is no leakage during compression. Tiangao designed structures and selected materials contrapuntally to achieve the best sealing. During production, we remove pollutants on the metal diaphragm surface and inside the pipeline. The process gas purity could reach 99.99999%. The diaphragm compressor is particularly suitable for compressing high purity, noble, precious, corrosive, radioactive, toxic and explosive gases.

99.99999%

Highest Gas Purity

Safety and Reliability Proven by the Market

Safety is our overriding object. Reliable technology is a prerequisite for safety and takes time to be proved. Until now, Tiangao diaphragm compressors, which have been used for more than 20 years, is still in normal operation. The safe and reliable Tiangao products have been verified under harsh conditions. Our product can meet the explosion-proof requirement of CT4, and various of safety protection devices could be installed to ensure safety.

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Multiple Safety Protection Design

. Diaphragm rupture detection and interlocking shutdown, pressure gauge display and over-pressure safety valve with discharge and relief functions.

. Lubricating oil pressure remote transmission, low pressure alarm and interlocking shutdown.

. Coolant cut-off protection.

. Suction pressure remote transmission, low suction pressure alarm and low-low interlocking shutdown.

. Discharge pressure remote transmission, high discharge pressure alarm，bypass and high-high interlocking shutdown.

. Discharge temperature monitoring at all stages.

. Discharge temperature high alarm, overheat interlocking alarm and shutdown.

. Lubricating oil temperature remote monitoring and interlocking protection. The oil heater could be installed to ensure the normal operation in low ambient temperature condition.

. Manual and automatic pressure relief valves in oil and gas circuits.

. Dual-oil-filter.

. Error-tolerance design to reduce the probability of equipment damage caused by human error.

. Tailored materials for different process gases.

. Utilize non-flammable and chemical resistant oil to compress strong oxidizing gas.

. The Bypass System could be utilized to reduce the impacts of frequent startup and shutdown.

. Large equipment could be equipped with vibration transmitter, vibration data remote transmission controlsystem, excessive vibration alarm and shutdown.

. Large machines could be equipped with main bearing high temperature alarm, high-high interlocking alarm and interlocking shutdown.

. Each stage could be equipped with safety valve. Suction safety relief valves are equipped at suction when compressing hydrogen to ensure the normal operation of each cylinder and pipeline pressure.

. Filters could be equipped at suction to ensure the durability of gas valve and diaphragm.

. Damper are equipped for all stages to ensure gas flow stability.

. Low piston speed design to reduce equipment vibration and extend diaphragm and gas valve life.

Automatic Light Unloading & Start-up System

The valves in the gas and oil circuits are automatically opened and closed by preset program to reduce the possibility of safety accidents caused by human error.

Anti-Hydrogen Embrittlement Design

Hydrogen embrittlement is a crack or damage phenomenon of metal caused by the material mechanical plasticity and performance decline under certain conditions. The hydrogen density and volume are tiny that could cause void growth and coalescence. Hydrogen atoms could penetrate metal easily and bring grain boundary diffusion. Hydrogen atoms recombine into hydrogen molecules in the grain boundary defects and continue to gather, resulting in increasing internal stress, and consequently the metal cracked.

Tiangao high-pressure hydrogen diaphragm compressor successfully overcome the cylinder stress crack by utilizing patented Composite Gas Head design. The hydrogen processing side adopts hydrogen embrittlement resistant materials while the external part adopts high strength steel to lower the cost while maintaining its structural strength.

200,000 Hours Main Parts Service Life Design

The crankshaft, crankcase, gas head, oil head, connecting rod and other main parts are designed to withstand 200,000 hours service life.

Stable & Reliable Oil Distribution System

Oil pressure makes gas pressure. Oil overflows at high pressure and be replenished at low pressure is the core theory of oil controlling system. Oil replenishment Technology is designed based on the Engineering Cybernetics, ensuring the stability of the oil pressure system. In a close-loop oil system, oil must be compensated after each overflow. Replenishment pump, regulating valve and check valve play crucial roles in oil distribution system. The Replenishment pump is used to replenish oil, the regulating valve is used to control oil overflow volume, and the check valve is used to prevent backflow.

The cleaner the oil is, the better the dynamic oil film sealing effect can be guaranteed, and the more stable the machine is. The Oil Filtration System is one of the essential factors to ensure the oil pressure stability. The lubricating oil after coarse filtration will be pressurized by the gear pump to the precision filter, and enters the replenishment pump. This process stops small particles from entering the replenishment pump and prevents plunger damage. At the same time, the pressurized lubricating oil can keep the replenishment pump working even if there is air insider the pump.

The Non-Oil-Perforated-Plate Design to reduce sealing and leakage surface, effectively control the diaphragm stress and improve the discharge efficiency and equipment operational efficiency.

The Degassing Technology of Oil Pressure System to achieve stable oil pressure.

The high efficiency oil heat exchanger to greatly reduce the lubricating oil temperature.

The Pressurized Lubricating Technology to improve the moving part bearing capacity. Oil film generates on the surface of friction pairs when the pressure oil has been injected, which effectively improves the lubrication between the friction pairs and dissipates the friction heat.

Return

The Cylinder and The Servo Valve

To Optimize High Discharge Pressure Large Flow and Low Temperature Rise

Diaphragm compressor pressurizes by changing the volume of the cavity contours. With a large surface area and volume, the diaphragm compressor can achieve 1:5 to 1:10 economic compression ratio or 1:20 maximum compression ratio. Benefits from its large surface area, the cylinder heat could be dissipated quickly. The compression process is a near-isothermal compression. Even in the condition of high compression ratio, there is no obvious temperature rise during compression that concurrently meets the requirements of high discharge pressure, large flow and low temperature rise.

Optimized cavity contour design. The traditional cavity contour design is based on the Kármán Equations, but the gas flow characteristics of hydrodynamics are neglected. Average diaphragm stress is not the only reason brings better fluidity. Better cavity contour design can improve the volumetric efficiency and increase flow and compression efficiency.

Energy Saving, Low Maintenance Cost & Longer Diaphragm Life

The Servo Valve

The Servo Valve Allows Oil Pressure to Be Adjusted
According to Gas Pressure, up to 20% Energy Saving

The servo valves could reduce 20% energy consumption and extend diaphragm life. During the operation, the pressure of storage tank influences the pressure of discharge, while oil pressure is changed in accordance with gas discharge pressure. The servo valve allows the oil pressure to be adjusted according to gas pressure, as consequence, the shaft power is adjusted to consume less energy and bring more efficiency.

The lower the discharge temperature, the higher the efficiency. Temperature control is an important means to improve operation efficiency. The Oil & Gas Cooling System enhances the efficiency and reduces power consumption. Tiangao has designed multi-layer coolant channels inside the cylinder to cool down the discharge temperature and reduces heat of gas from transmitting to oil to ensure the lubrication effect of hydraulic oil. The Dual Intelligent Oil Cooling System could be installed which can be automatically turned on and off according to oil temperature, better controlling the temperature and saving energy.

Longer diaphragm life and less diaphragm maintenance costs. All designs aim to optimize diaphragm service life and maintenance cost. The normal service life of diaphragm is 4,000-8,000 hours. The longest diaphragm life of Tiangao diaphragm compressor reached 20,000 hours.

2.0 MPa minimum unloading pressure. The hydrogen refueling station can fill 45.0 MPa tanks by diaphragm compressor when the tanks pressure is greater than 8.0MPa and fill 25.0 MPa tanks when the pressure is less than 8.0 MPa without residual gas compressor. The minimum unloading pressure could reach 2.0 MPa, greatly reducing the economic loss caused by residual gas in trailer.

Up to 20 %

Energy Saving by Servo Valve
20000 Hours

Longest Diaphragm Life
2.0MPa

Minimum Unloading Pressure
The Oil & Gas Cooling System

Control Temperature & Save Energy

The Dual Intelligent Oil Cooling System

Automatically Open & Close According to Oil Temperature,
Better Controlling Temperature & Saving Energy

Intelligent Operation Management System Improves Customer Service Operation and Maintenance Efficiency

Based on data modeling and IoT technologies, Foran Tiangao is researching Operation Management System which could achieve remote data monitoring, fault alarm, fault diagnosis, maintenance advisor and fault prediction to accomplish 7×24 hours monitoring, equipment maintenance cost and unscheduled downtimes reduction.