Liu Xiaodong, Su Baicheng, He Tao
(Ningxia Baofeng Energy Group Co., Ltd., Yinchuan, Ningxia 750001)
[Abstract]:In response to the problem that the designed flow rate of the compressor unit significantly exceeds the production operation requirements, resulting in energy waste, a solution based on the Invention Problem Solving Theory (abbreviated as TRIZ) is proposed. Through functional model analysis and causal chain analysis of the compressor unit system, the fundamental cause of energy waste in the compressor unit was determined. Using tools such as physical contradictions, matter-field analysis, and technical contradictions, a design scheme was proposed to achieve automatic control by optimizing the anti-surge line of the compressor. After application verification, this scheme reduced the opening degree of the anti-surge valve from 38% to 17%, achieving an energy saving of 14.8%, providing a reference and technical support for the optimization of compressors in similar devices.
[Key words]:TRIZ theory; compressor; surge; functional model; causal chain analysis
Chinese Library Classification Number:TH45 Document Code:B
Article Number:1006-2971(2026)01-0051-06
Introduction
The Theory of Inventive Problem Solving (abbreviated as TRIZ) was developed by G. S. Altshuller from the former Soviet Union. Based on the analysis and study of 2.5 million patents from various countries, he summarized the laws that various technologies follow during their evolution, establishing a methodological system that can effectively describe the development of new technologies. G. S. Altshuller believed that the basic principles of invention problems are objectively existent, and these principles were organized into the TRIZ theory. Those who master this theory make invention problems predictable [1]. The TRIZ theory is also regarded as a toolkit of a series of analytical methods and solutions [2].
The TRIZ theoretical system includes the nine-screen method for assisting innovation, the ultimate ideal solution, the little man method, the STC operator, and the goldfish method, etc.; for analyzing problems, there are functional analysis, causal chain analysis, contradiction analysis, matter-field analysis, and the ARIZ algorithm; for solving problems, there are 40 inventive principles, separation principle, 76 standard solutions, knowledge effect library, and tailoring [3].
The application of TRIZ in the field of production and manufacturing mainly lies in enhancing production efficiency, improving product quality, optimizing process technology, and avoiding patent infringement, etc. [4]
In the field of energy conservation, CHIU et al. [5] successfully developed an environmentally friendly paint for roof energy conservation using the TRIZ technology. The results of the heat resistance test showed that the new material could save electricity by more than 20%. Liu Xiancheng et al. [6] applied the TRIZ method to the energy-saving renovation of reciprocating compressors. By adding an air valve regulation system and changing the crankshaft amplitude, they achieved the purpose of regulating the compressor power. Qi Haiyuan [7] combined TRIZ with the theory of building energy conservation construction system to construct a building energy conservation technology evaluation and innovation model. Through wall design, the effectiveness of the method was verified. Zhao Cunyou et al. [8] used the ARIZ algorithm in the TRIZ theory to analyze the reasons for the high energy consumption of the coal mining machine's cutting drum. By exploring the derived resources, an effective energy-saving solution was formed. Jin Lin et al. [9] improved the design of the heat exchanger of the printing machine by using the TRIZ theory. By selecting fin-coated tubes with appropriate fin coefficient and emissivity, the heat generation efficiency of the heat exchanger was improved. Alvarez et al. [10] proposed a renewable energy ecological innovation model based on Exergy analysis, TRIZ theory and knowledge management.
During the operation of a centrifugal compressor, when the flow rate drops to a certain level, flow instability, or surge, will occur. Surge is an inherent characteristic of centrifugal compressors and can cause significant impacts and intense vibrations inside the compressor, and in severe cases, it can lead to equipment damage and pose a threat to personnel safety [11]. Therefore, in the operation control of the compressor unit, preventing surge phenomena is extremely important. The performance curve of the compressor is obtained through testing under certain inlet conditions and gas composition. The energy consumption value of the compressor is generally calculated based on the performance curve. Research shows that the error in calculating operating parameters using the theoretical performance curve can be as high as 20%, and thus the compressor operation plan formulated based on this will lose its energy-saving nature [12]. The connection of the performance curve at the highest point under different rotational speeds forms a limit curve indicating the occurrence of surge in the compressor. If the operating point of the compressor is on the left side of the curve, surge will occur [13]. When the operating conditions change, the performance curve will shift, and the shift is highly uncertain. Therefore, certain methods must be adopted to obtain the actual performance curve [14]. Xu Ye et al. [15] proposed a method for diagnosing compressor surge based on multi-source information such as flow, pressure, and vibration; ALSUWIAN et al. [16] reviewed the surge prevention control system of the compressor and advanced fault-tolerant control technology; Zhang Ping et al. [17] improved the particle swarm IPSO algorithm to optimize the LSSVM model to predict the performance curve of the centrifugal compressor; Chen Lijiong et al. [18] proposed an adaptive performance curve generation method based on ANFIS, with an error of less than 3% compared to the actual operating curve.
Systematic analysis
2.1 Functional model analysis
The functional model describes the functions of the engineering system and its subsystems, as well as useful functions, defective functions, performance levels and costs. This model only expresses the interaction relationships of system components and is independent of the sequence of function realization. Based on this model, it is possible to determine the causes of problems and the conflict areas related to the problems due to the interactions between components [19]. In this paper, the conflict areas are determined first by establishing the functional model, and then the causal chain is established to determine the conflicts. The compressor unit system is defined as the engineering system, and the system components are the motor, speed increaser, compressor, outlet regulating valve, inlet regulating valve, anti-surge valve, CCS system, etc.; the super-system components are electrical energy, air, operators, catalyst activity. The functional relationships among the components of the engineering system are analyzed, and a functional model is created, as shown in Figure 1.
Through the analysis of the functional model diagram, it can be concluded that the functional deficiencies of the engineering system are: the compressor fails to supply the required amount of air to the regenerator excessively; the CCS system fails to accurately measure the catalyst activity; and the operators' inability to control the inlet and outlet regulating valves and the anti-surge valves is detrimental.
2.2 Cause-and-effect chain analysis
As a key tool for analyzing problems within the TRIZ theoretical framework, the causal chain analysis identifies the key causes of the engineering system, discovers the underlying and profound reasons within the system, links the target problem with each of the underlying flaws, and thereby finds the breakthrough point for solving the problem [20].
Due to the replacement of the efficient catalyst in the reaction section, the demand for regeneration air has decreased compared to the original design. A large amount of air is vented through the anti-surge valve. Regarding the problems arising from this research, the high energy consumption of the compressor unit is defined as the initial problem. The causal chain method is used to analyze the compressor system, and the analysis results are obtained, as shown in Figure 2.
The analysis results initially identified three key technical issues that could potentially lead to high energy consumption of the compressor unit: excessive air being discharged locally, large opening of the anti-surge valve, and limited application of automation technology.
Applying the TRIZ theory for problem-solving
Based on the functional defects and key issues identified through the functional model analysis and causal chain analysis, improvement plans for the compressor system were proposed by applying the nine-screen analysis method, the life curve, the matter-field analysis, the physical contradiction, the ultimate ideal solution, the technical contradiction, the resource analysis, and the STC operator. Due to the limited space, this article only provides a detailed description of the application of some of these methods.
3.1 Solution based on physical contradiction
According to G. S. Altshuller's definition of physical contradictions, when the engineering parameters of a technical system have opposite requirements, a physical contradiction occurs.
Describe the key issues that conform to physical contradictions in accordance with the norms, separate the two sides of the contradiction based on the core idea of resolving the contradiction, and formulate specific solutions referring to the corresponding innovative principles [21]. The separation idea of physical contradictions is shown in Figure 3.
To achieve the goal of reducing the energy consumption of the compressor unit, the opening degree of the anti-surge valve is defined as a physical contradiction. To ensure that the compressor does not experience surge, the anti-surge valve needs to be opened wider. However, to reduce the energy consumption of the compressor, the anti-surge valve needs to be closed narrower. According to the standard expression of physical contradiction, it can be described as: The compressor system needs to open the anti-surge valve wider in order to prevent the occurrence of surge.
To reduce energy waste, the anti-surge valve in the compressor system needs to be closed to a smaller degree. To achieve the ideal state of the technical system, the contradictory requirements of this parameter can be met under different conditions of the anti-surge valve. By adding guiding keywords that describe the condition state, the physical contradiction is further described as follows: When the operating state of the compressor approaches the surge line, in order to prevent the occurrence of surge, the anti-surge valve needs to be opened wider.
When the operating state of the compressor deviates from the surge line, in order to reduce energy waste, the anti-surge valve needs to be closed slightly.
At this point, the contradictions are separated based on the conditions. The innovative principles involved in the condition separation method include the division method, the combination method, the nesting method, the reverse method, the curve method, the feedback method, the substitution method, and the performance transformation method, etc.
Regarding the issue of reducing the energy consumption of the compression unit, the innovative principle "division method" was selected to formulate the solution. The specific plan is as follows:
On the right side of the surge line, draw a line as a buffer. When the operating state of the compressor approaches this line, open the anti-surge valve wider to ensure that the compressor does not experience surge; when the operating state of the compressor is far from this line, close the anti-surge valve to reduce energy waste. This method resolves the physical contradiction where the anti-surge valve needs to be opened wider and also needs to be closed narrower.
3.2 Solution based on matter-field analysis
The object-field model analysis is an important problem description and analysis tool in the TRIZ theory, which can intuitively represent the system problem; during the problem-solving process, the standard solution can be sought to improve or solve the problem [22]. The general process of applying object-field analysis to solve problems is shown in Figure 4. G.S. Altshuller believes that all functions can be decomposed into two substances
And there is a kind of field, which consists of three elements of two substances and one field, namely the object of action, the tool, and the field. BELSKI [23] proposed a standardized process for analyzing and solving technical problems based on the object-field model. After establishing the solution model, specific solutions can be obtained based on the interaction forms between the substances [24].
Based on the functional model, the physical-field model of key defects is established, as shown in Figure 5. The two substances of the system are the compressor unit and the regenerator. Their interaction is an electric field. The dotted line indicates that the compressor unit has a detrimental effect on the regeneration supply air of the regenerator.
For non-effective and complete models, the corresponding solution in the TRIZ theory for the 1.2 type standard solution "Disassembly-Field Model" should be adopted to solve the problem. The general solution methods for the problem model include five options: (1) "Introduce S3 to eliminate the ineffective effect"; (2) "Introduce improved S1 or S2 to eliminate the ineffective effect"; (3) "Introduce matter to eliminate the ineffective effect"; (4) "Use field F2 to counteract the ineffective effect"; (5) "Eliminate the influence of the magnetic field". Here, in order to reduce the excessive function of the compressor unit for the regenerator regeneration, we choose the 2nd standard solution to formulate the plan. The specific plan is:
Based on the solution of "introducing improved S1 or S2 to eliminate the ineffective effect". The existing compressors are driven by fixed-frequency motors, and the air volume cannot be adjusted through the input side. We have modified the driving motor of the compressors to a variable-frequency one to achieve adjustable air volume, as shown in Figure 6.
3.3 Solution based on technical contradiction
A technical contradiction refers to the situation where, in order to achieve the goals of the current technical system, the parameters corresponding to two different functions of the system are mutually exclusive. That is, when one parameter is improved, the other parameter deteriorates [25]. The steps for resolving technical contradictions using the TRIZ theory are as follows: clearly define the problem and identify the contradiction point of the problem; convert the problem into a standardized expression form of technical contradiction; apply the contradiction matrix to find the corresponding inventive principle; based on the inspiration of the inventive principle, propose a solution [26]. The process of solving problems based on technical contradictions is shown in Figure 7.
Based on the results of the causal chain analysis, the issue identified is: The opening of the anti-surge valve is too large. Technical description: If the anti-surge valve is blindly reduced in size in an attempt to reduce the energy loss of the compressor unit, it may cause compressor surge.
Define the technical contradiction. The parameters to be improved: No. 22 energy loss; the parameters that have deteriorated: No. 27 reliability.
Search for the contradiction matrix and obtain the corresponding inventive principle: No. 11 - Precautionary Measures.
Inspired by this invention principle, a solution was obtained: draw the actual anti-surge line of the compressor and implement pressure line control.
Based on the results of the causal chain analysis once again, the second problem identified is: The application of automation technology is limited.
Technical issue description. If the anti-surge control of this compressor unit is changed to automatic adjustment, it will enhance the automation level of the compressor unit, reduce the labor intensity of the staff, but increase the complexity of the system and the possibility of instrument control system failures.
Define technical contradiction. The parameter to be improved: No. 38 - Automation level;
The deteriorated parameter: The complexity of No. 36 device.
Search for the contradiction matrix and obtain the corresponding inventive principle: No. 24 - Principle of Using an Intermediate Medium.
Inspired by this invention principle, a solution was obtained: an anti-surge algorithm module and a control operation module were added to the compressor surge control operation mode. When the surge control operation mode is in the automatic state and the control operation module is activated, at this time, the anti-surge algorithm module in the surge control operation mode is associated with the anti-surge valve control operation module. Eventually, the system can automatically monitor the surge trend of the compressor unit. If a surge occurs, the system will automatically open the compressor anti-surge valve to ensure that no surge occurs.
3.4 Summary of the Plan
By applying the functional analysis and causal analysis of the TRIZ theory, and utilizing 10 innovative method tools such as the nine-screen analysis method, the life curve, resource analysis, ultimate ideal solution, technical contradiction, physical contradiction, STC operator, and matter-field analysis, 23 concept schemes were obtained. Table 1 summarizes the schemes.
An evaluation model was established, as shown in Table 2. The 23 innovative schemes were sorted out and evaluated, as shown in Table 3. The top three schemes in terms of comprehensive score, namely 11, 21 and 22, led to the design scheme of achieving automatic control by optimizing the compressor anti-surge line.
Application verification
4.1 Implementation of the plan
First, test the actual surge line of the compressor
(1)Confirmation of the operating status of the unit: The mechanical operation of the unit is normal, the measurement instruments related to the surge test are functioning properly, and the main process parameters of the unit are normal.
(2)The preparatory work is completed. The instruction for the test preparation is received. The anti-surge control mode is set to semi-automatic, the operation mode of the unit is switched to automatic, and the opening degree of the inlet valve is adjusted to the test value.
(3)Use the "Move Vibration Suppression Line" button to shift the vibration suppression line to the left, so that the distance between the anti-vibration line and the working point is within 1% of the distance. Then start the test.
(4)Upon receiving the start test instruction, gradually close the anti-surge valve. When the flow rate decreases and the operating point approaches the surge control line, use the moving surge line button to shift the surge line to the left. Continue to close the anti-surge valve until the test termination conditions are met. Then, end the experiment at this point.
(5)Adjust the opening degree of the inlet valve of the unit, and proceed with the next steps (3), (4), and (5) as per the procedures. Continue until all the experiments are completed.
(6)The actual surge line and the optimized anti-surge line are shown in Figure 8.
4.2 Effect verification
When the compressor is operating at 100% of the device's load, the anti-surge valve opens at 17%, which is 21% lower than the optimized value. After controlling with the optimized anti-surge line, the energy-saving rate reaches 14.8%. The optimization effect is better than expected and the performance acceptance is qualified.
After the project is completed, the annual electricity savings amount to 2,880,914 kW·h. With the electricity cost calculated at 0.54 yuan per kW·h, the annual cost savings will be 1,556,000 yuan.
Conclusion
This paper analyzes and studies the phenomenon that the designed flow rate of the compressor unit significantly exceeds the actual demand for production operation, and the imbalance in resource allocation. The main contents completed include the following aspects:
(1)By applying the functional model analysis and causal chain analysis in the TRIZ theory, the problems existing in the air supply system for the regeneration chamber of the compressor were identified: excessive air was discharged directly, the opening degree of the anti-surge valve was large, and the application of automation technology was scarce.
(2)Based on the innovative methods and tools such as physical contradictions, material-field analysis, and technical contradictions in the TRIZ theory, and referring to the invention principles and standard solutions, a design scheme for achieving automatic control by optimizing the compressor anti-surge line was proposed.
(3)The implementation results show that, by referring to the optimized anti-surge line control, the anti-surge valve can be closed to a smaller extent under the condition of ensuring the safety of the compressor unit, achieving automatic control. This reduces the labor intensity of the operators and the risk of misoperation. The energy consumption data after operation also indicate that this solution can effectively reduce the energy consumption level of this unit, providing reference and technical support for the optimization of compressors in similar installations.
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Author Profile:Liu Xiaodong (1986 - ), male, senior engineer, master's degree holder, mainly engaged in equipment fault diagnosis and technological upgrading.