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<p>Reciprocating compressors are widely used in petrochemical, nuclear power, and energy industries, with intake valves often of the self-acting type. Relying on gas pressure to drive opening and closing, these valves suffer from high flow resistance, delayed response, and elevated energy consumption, limiting overall efficiency. Although rotary stereoscopic valves improve single-stage flow capacity and suction efficiency, in two-stage systems, insufficient second-stage flow capacity after first-stage enhancement creates inter-stage mismatch, forming a new energy bottleneck. This study proposes a system-level flow capacity matching design to align the second-stage valve flow with the first-stage exhaust volume. A system energy consumption model considering inter-stage pressure distribution, valve flow resistance, and volumetric efficiency coupling is established to reveal how second-stage valve capacity impacts overall compressor energy use. A response surface method quantifies the relationship between flow port number, contact surface tilt angle, and flow path angle with pressure loss and flow coefficient, guiding multi-parameter structural optimization aimed at minimizing energy per unit discharge. Results show that when the valve top outer diameter is 30&#xa0;mm, with 10 flow ports, a 70° contact surface tilt, and a 16° flow path angle, the valve achieves optimal performance (flow coefficient 0.394, pressure loss 10916&#xa0;Pa). Experiments indicate that the optimized secondary rotary stereoscopic valve increases discharge by 8.9% and reduces specific energy consumption by 6.0%. This work reveals the influence of secondary valve structural parameters on system energy consumption from a flow-matching perspective and establishes a flow-capacity–driven structural optimization methodology, providing theoretical and practical guidance for energy-efficient reciprocating compressor valve design and system-level optimization.</p>

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Energy-saving and efficiency enhancement of reciprocating compressors: study on flow capacity matching mechanism and flow path structure optimization of secondary rotary stereoscopic valves

  • 期刊论文

  • 发表日期：

    2026年7月2日

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  • Xiao Hong,
  • Weilin Cui,
  • Dexi Wang,
  • Dajing Liu

摘要

Reciprocating compressors are widely used in petrochemical, nuclear power, and energy industries, with intake valves often of the self-acting type. Relying on gas pressure to drive opening and closing, these valves suffer from high flow resistance, delayed response, and elevated energy consumption, limiting overall efficiency. Although rotary stereoscopic valves improve single-stage flow capacity and suction efficiency, in two-stage systems, insufficient second-stage flow capacity after first-stage enhancement creates inter-stage mismatch, forming a new energy bottleneck. This study proposes a system-level flow capacity matching design to align the second-stage valve flow with the first-stage exhaust volume. A system energy consumption model considering inter-stage pressure distribution, valve flow resistance, and volumetric efficiency coupling is established to reveal how second-stage valve capacity impacts overall compressor energy use. A response surface method quantifies the relationship between flow port number, contact surface tilt angle, and flow path angle with pressure loss and flow coefficient, guiding multi-parameter structural optimization aimed at minimizing energy per unit discharge. Results show that when the valve top outer diameter is 30 mm, with 10 flow ports, a 70° contact surface tilt, and a 16° flow path angle, the valve achieves optimal performance (flow coefficient 0.394, pressure loss 10916 Pa). Experiments indicate that the optimized secondary rotary stereoscopic valve increases discharge by 8.9% and reduces specific energy consumption by 6.0%. This work reveals the influence of secondary valve structural parameters on system energy consumption from a flow-matching perspective and establishes a flow-capacity–driven structural optimization methodology, providing theoretical and practical guidance for energy-efficient reciprocating compressor valve design and system-level optimization.